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930 Trans - Full On Synchro Change

I am preparing to replace some or all of the synchro rings, synchro hubs, sliders, and other parts as necessary in my 930 4-peed trans. There is a very useful article on this task for the 901 trans at the following link:

http://home.san.rr.com/pb914/rebuild/

The author makes it clear that the "Shift Fork Alignment Tool" is critical for proper reassembly. Here is what the tool looks like for the 901:



I have been searching for the 930 version of this tool without success. Does anyone know:
1. Where to get one?
2. How to make one?
3. How to get around it?

Thanks,
Steve Buchanan
Old 04-29-2005, 08:47 AM
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baum tool 9106

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Old 04-29-2005, 09:18 AM
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I have just replaced all the synchros, dog teeth, a few gears (for different ratio) on my 930 box with help from JW and others on this forum and my mechanic.

I didn't need this jig for the job. My mechanic scribe how & where the fork was before disassembly and reinstall the fork per the scribed line. Not 100% precise and I have barely put 20 miles on the car so far but all seems to work perfectly. I'll find out when I put her through the track next week
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Old 04-29-2005, 10:11 AM
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the fork may or may not be in the correct position when you disassemble. i've seen plenty of them that were off a bit. the idea is to center the shift sleeve between the gears on either side of it. in the end, it's an eyeball job, jig or not.
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Old 04-29-2005, 11:26 AM
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John, so it should be a simple work/don't work situation then? If the fork is off, then there will be drag or hard to engage? If not, then the fork is probably set within spec?

thanks.
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Old 04-29-2005, 11:48 AM
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hobieboy,

It sounds like you did not need any special tools. Maybe the synchro hub removal tool?

Also, what did you use for documentaton? Was it the Posrche Factory Workshop Manuals?
Old 04-29-2005, 04:01 PM
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Yes, I purchased the 1st/2nd synchro removal tool; though I (we) still haven't figured out how it would work for the 1st gear I didn't need 3rd & 4th as I was replacing the gear set.

Resources I used: Pelican BBS factory manual and the in-depth know-how of my mechanic, whom I went to after the initial disassembly (since I was running out of time & courage).

The 930 box really is a lot simpler than the 915. You don't need to remove the pinion shaft, for example, to replace synchros/dog teeth. But you do need a press (one of the reason I went to my mechanic) to do a proper job.
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Old 04-29-2005, 04:46 PM
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the larger syncro removal tool works on 1st, not 2nd, because 2nd gear is the same basic diameter as the toothed ring, so there is no way to support the gear in a press and push the teeth off with the tool. you have to use a sharp chisel and hammer to work it off 2nd. use eye protection. the smaller tool works fine on 3rd/4th. the tool is expanded into the inner snapring groove, the gear is supported on each side on press plates, and then the press butts up on the end of the tool and presses the ring off.
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Old 04-29-2005, 05:59 PM
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Hi John,

Yes - your description is exactly what I faced with at the time & we did exactly what you described. The tool can be used to "easily" put both gears back on though.

So at least now I don't feel too stupid - thought its just me who didn't know how to use the tool
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Old 04-29-2005, 07:01 PM
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