Unfortunately post the calipers and lines, we still had the phantom brake fluid loss.

I was hopeful, but not optimistic that it would stop happening. Next on the list was a master cylinder - and the quest to get more and more of the parts in the vehicle replaced with new continues. I did a ton of research and was thinking the master cylinder was a bit beyond what I felt comfortable digging into myself, so off to one of the local air cooled specialists Maverck went.

It indeed was leaking from the master cylinder and unfortunately the fluid damaged the booster (man those things are expensive). I figured if I was going to spend $$ making something right the brakes were not a bad place to invest! So now the car has all new calipers, pads, booster, master cylinder, and fluid.

Furthermore, I had new front / rear Bilsteins and Turbo tie rods in the garage that I was planning to install at some point and figured while it was in the shop why not have them toss them in.

Getting the car back was amazing. All new brakes - all new suspension bits - it drives SO MUCH better now - just in time for the MN summer. Time to rack up the miles!

The recent post on "unpolishing wheels" motivated me to spend a bit of time in the garage this am.

https://forums.pelicanparts.com/porsche-911-technical-forum/1161667-how-unpolish-mirror-style-wheels.html

I never loved the polished Fuchs on the car. I have been watching for a used set of black ones, but also found a picture of a silver car with more of an RSR type finish that I fell in love with so I figured - I likely won't make the wheels worse and can always re-polish them if it didn't work out.

I certainly need to spend a bit more time with higher grit sandpaper, however I think it is moving in the right direction! At this point all I used is a red scotch brite on the centers. Well worth an hours worth of work!!

Before:
<a href="https://ibb.co/HKjv1bv"><img src="https://i.ibb.co/x2NvPBv/IMG-1668.jpg" alt="IMG-1668" border="0"></a>

<a href="https://ibb.co/7RCg8Zh"><img src="https://i.ibb.co/Hx4N1bZ/IMG-1945.jpg" alt="IMG-1945" border="0"></a>

After:
<a href="https://ibb.co/7jZKwbY"><img src="https://i.ibb.co/bQCXS7W/IMG-1951.jpg" alt="IMG-1951" border="0"></a>

<a href="https://ibb.co/3ydvywm"><img src="https://i.ibb.co/0j2Kjky/IMG-1942.jpg" alt="IMG-1942" border="0"></a>

Well - the car is back under the knife at one of our local air cooled specialists.

I had posted about the car popping out of first and feared dog teeth. Played with adjusting the coupler yet could not make first usable.

Babied it to the shop without using first this week and about 1 mile from the shop - starting in second on an uphill started hearing something bouncing around the tranny!!!!!

So a tranny rebuild it is. When I get it back the car will have new suspension, new brakes, and a rebuilt tranny. I knew the vehicle was going to need sorting when we purchased it - and that has certainly been the case.

I will post details on what is found and now am antsy to simply get the car back to rack up miles in our MN summer. Stay tuned!

Tranny rebuild in progress - the case will be opened up this week and I will post what they find. This is the first time we have had the engine out since purchasing Maverck 18 months back, and I guess it was just a matter f time!

Since I am this deep in - I may regret asking - however what would be on your "while you are in there" list. The shop already brought up:
-Oil pressure sender
-Breather hoses
-Throttle linkage bushings

What else comes to mind?

http://forums.pelicanparts.com/uploa...1720481510.jpg
http://forums.pelicanparts.com/uploa...1720481510.jpg
http://forums.pelicanparts.com/uploa...1720481510.jpg
http://forums.pelicanparts.com/uploa...1720481510.jpg
http://forums.pelicanparts.com/uploa...1720481510.jpg

Since your engine is out too for some reason perhaps address some or all of the triangle of death stuff
https://forums.pelicanparts.com/porsche-911-technical-forum/814646-triangle-death-wimps.html

Also a good time to install Wevo blue engine and trans mounts

Thanks!!!

So - the breakdown started with a double brake band that came loose, started making its way around the tranny and causing issues. Unfortunately- it is leading to a full rebuild of all gear sets. Nice thing is it will be as good as new when done!!!

Pics forthcoming of the broken pieces when I get them from the shop.

How many folks in this situation go with a taller fifth gear?

I had the exact same issue as you, popping out of first. When I drained the gear oil, I found about a dozen chunks of dog teeth. No bueno.

Off to my rebuilder, and a lot of $$, and I have a basically new box. This includes a taller 5th gear, which I’m happy with (80 MPH at 3K RPM, previously was about 3,500, so I am good with a planned trip which includes highway driving).

Good luck with yours!



http://forums.pelicanparts.com/uploa...1720570483.jpg
http://forums.pelicanparts.com/uploa...1720570483.jpg

Thanks! What are the specs on your fifth gear? I am thinking I should do the same.

It was a Z 29:21. Took a couple of weeks to source.

Thanks!

I have the higher 5th gear in my car too. Really makes the car more relaxed at highway speed. No downsides that I can see, because I never get above 4th on the rare occasions I take it to a track.

Thanks!!

Some of the insides!

You can see the pieces of the broken brake band that was bouncing around the tranny in a few of the photos.

http://forums.pelicanparts.com/uploa...1721242681.jpg
http://forums.pelicanparts.com/uploa...1721242681.jpg
http://forums.pelicanparts.com/uploa...1721242681.jpg
http://forums.pelicanparts.com/uploa...1721242681.jpg

When mine broke a few years ago, a chunk of the brake band wedged itself between two gears. Made for a lot of fun...and a terrific noise.

Yea - when mine started making noise, literally on the way to the shop - it was a pretty big O SH%# moment.

“Terrific noise” is a perfect explanation!!

The shop told me some teeth are sheered off some of the gears…..

I was doing ~60mph in fourth gear when the second gear brake band fragged. (accelerating out of a construction zone) I still have most (all?) of the old broken bits we pulled out of the gearbox that week. Bad times make for good stories, right? :D

That sounds crazy @chrisbalich! You are so right - the stories certainly are part of building a relationship with the vehicle over time.

Tranny is back together and everything is going back in Maverck as we speak. I am so excited to get the car back and take it for a rip.

Ultimately they replaced:
-All gears and synchros
-Vacuum / breather hoses on the back of the motor with it out
-Oil pressure sending unit
-Motor and tranny mounts

All items they replaced appeared to be the originals from 1981.

http://forums.pelicanparts.com/uploa...1721838115.jpg
http://forums.pelicanparts.com/uploa...1721838115.jpg
http://forums.pelicanparts.com/uploa...1721838115.jpg
http://forums.pelicanparts.com/uploa...1721838115.jpg
http://forums.pelicanparts.com/uploa...1721838115.jpg

Back on the road after the rebuild for the last couple of days!

Boy it felt good! I don’t know what is better - the rebuilt 915 or how much better the motor is running after most of the vacuum hoses were replaced with the car re-timed, and the fuel delivery tweaked. The shop also told me the throttle linkage was hitting a clamp at about 3/4 throttle!

I also had a high idle around 2k before the service (likely vacuum leak related) which is now resolved!

Next up, take the sunroof apart to get it working again and replace the seals.

http://forums.pelicanparts.com/uploa...1723510107.jpg

Those hips in the morning sun!! Days like this, walking up to the car, I forget the clear coat is hammered in many places!

<a href="https://ibb.co/nmnWtvR"><img src="https://i.ibb.co/SydLG8J/IMG-3274.jpg" alt="IMG-3274" border="0"></a>

Just been driving the crap out of the car post the transmission, brakes, and suspension work that took up the start of the season. Man o man it is fun to build a relationship with these cars!

Chasing down a fuel smell in the cabin after fill up right now. Just ordered some parts from our host to hopefully make quick work of that.

Good to see it's back on the road again in such a short amount of time! Keep enjoying it!