G50 Cross-shaft

Will Schulz · 03-20-2005, 06:34 AM

Can the cross-shaft for a G50 transmission be installed backwards? I'm looking at mine and there isn't a hole with threads to attach a puller. This shaft was behind a small plug.

Britwrench · 03-20-2005, 07:59 AM

No, you could have the old design (pre-about 88) shaft, but even those ones did have a threaded hole. You will need to remove it and find out exactly what parts are there. The update, which requires machining the case with a Porsche special tool and replacing all the bits, including lever, shaft, bearing and seals is desribed in the Porsche Parts booklet form the late 90s. Or there is a aftermarket one which doesn't involve machining. You will need to replace the release lever as it's been updated and use the Porsche grease.
Never grease the clutch guide tube (which is also updated and different)if using the Sachs clutch with the "plastic" insert in the release bearing.
All the above depends on the year of your trans.

Or yes, someone could have put the shaft in backwards...not too clever.

Will Schulz · 03-20-2005, 08:15 AM

This is a 89 model and according to the records has been update.
I guess the only way to remove the shaft is to drill and tap a pull hole.

Britwrench · 03-20-2005, 08:22 AM

Yes, you could do that. If trans is out, you might want to try releasing the clutch cover bolts evenly (with the trans to engine nuts loosened but not removed) until you can pull the trans off with the clutch cover still attached to the release lever. Then unclip the release bearing circlip and the plate will come off and release lever shaft pushed out. There is a hole on the lever bearing casting on the right side of trans so you might be able to tap the bearing and shaft out to make life easier.

Will Schulz · 03-20-2005, 08:47 AM

I'll try that and let you know how it turns out. Thanks so much for your help, Will

Will Schulz · 03-20-2005, 11:03 AM

The cross-shaft was installed backwards.

After unsecuring pressure plate and removing trans from engine, I wasn't able to remove pressure plate from the bell housing. I got the shaft out by blowing compressed air onto the needle bearing housing which made it pop out. Also found the two screws for the throw-out bearing support missing. Thanks so much for your earlier advise. Having the transmission seperated for the engine made it much more manageable. Thanks again, Will

Britwrench · 03-20-2005, 11:17 AM

Well done!! Of course, I'm wondering how anyone would put the shaft the wrong way round in the first place......

When putting it all back together; assemble the shaft, seals and bearings on the bench. I use a long M6 bolt and nut to hold the left side(driver's side) bearing on and enable the shaft to be fed in carefully. Once the shaft is in the bolt will just unscrew and the shaft will remain in the right position.

Will Schulz · 03-21-2005, 02:42 AM

My clutch guide tube has been updated to the smaller size, but the throwout bearing doesn't have the plastic insert. Has the plastic worn away or were the some made like this?

Britwrench · 03-21-2005, 06:31 PM

Have only seen updated release bearings with the insert. If it's a Sachs part it will have one. Maybe someone, you know, the guy who installed the release lever shaft backwards, used the old release bearing.

The updated release bearing ID: 32.00mm (was 34.00mm)
Part number 950 116 080 07 (was 950 116 080 05)

The updated guide sleeve OD: 31.80mm (was 33.80mm)

Will Schulz · 03-22-2005, 02:21 AM

After cleaning and looking closer at the T.O. bearing I can now see a thin plastic insert. Sorry!

What type of grease should I use on the cross-shaft needle bearings? Thanks for all your help!

Britwrench · 03-22-2005, 04:09 AM

Porsche makes a grease for this purpose. The dealer will have it in stock. If you know them well enough, the techs might let you have enough to do the job.
Lube the shaft, bearings, the ears on the release lever where it touches the release bearing and the splines on the transmission shaft.
Use an anti-seize grease on the end of the release lever where the slave cylinder rod touches.
As I said before, the release guide tube and bearing insert must be dry.