915 Transaxle Rebuild

Well, I had my car in the shop this weekend for a brake fluid swap, mixture adjustment, tech. inspection for this Bogus Basin Hill Climb coming up this week end and my worst fears were confirmed about my transmission. Plain and simple...the synchros are going out. They have acted this way since I bought the car so I don't really think it had reached "critical mass" but I do want to avoid any further damage than could be prevented. I guess it is expected on a car with 216,000 miles on it. But now I am facing a tough decision. "Have mine rebuilt or buy a rebuilt unit from a place like Vertex". This is going to be a big deal for me no matter what. Has anyone ever purchased a rebuilt 915 from Vertex? My mechanic says that I am looking at at least $1500-1600 for him to rebuild mine and replace all of the rings and any dog teeth that might be damaged. I can get a rebuilt unit from Vertex for like $1049. The only problem is that the one person that my mechanic says he knows delt with them said that the guy had trouble with the core charge refund. I don't know how much of this to believe...I mean, sure maybe he did get stiffed or maybe his gearbox "was" trashed. There is just no way of telling. I also have to take into account that my mechanic also probably "Wants" to rebuild mine...$$$$
What are my options? I am almost to the point where I think I could drop the engine and gearbox, and preform a swap. I bet I could save a little by doing it myself, rather than having my mechanic do it. What is involved with this operation? Any specific tools that are needed that are one of a kind items?
I'm scared guys...but I guess I'll figure something out.
Thanks

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Leland Pate

___79 SC Targa

You know, it really sucks you have to worry so much about dealing with places of business, what happend to integrity??

Just my .02

Here's my take on these situations. Your tranny needs repair @ $1500. Used tranny runs $1000. You are familiar with your tranny, you know nothing of the used/rebuilt one. When yours is rebuilt you know it will be good for a long time. If the used/rebuilt unit fails you're screwed. I'd pay the $500 for piece of mind.

Rent car,a garage and spend $350 on some jacks and tools and do it yourself .
The parts shouldn't cost more than $400.00 and you will have a better trans rebuild than some BS shop will do.
You can rent the trans tools from Pelican and they probably can help you also

You might want to consider getting an earlier 915 with the 7:31 ring and pinion arrangement. That would transform a repair into an upgrade. Warren has written extensively on this on this board recently. If top speed isn't your priority, you could give your low end a real kick in the pants with a tranny change.

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Jack Olsen
1973 911 T sunroof coupe

Lee, I don't think you need to be scared, and I think you can handle the swap yourself!
First of all, I don't think you have to be in a rush to decide which source to get a rebuilt transaxle from. What brand of gear oil did you put in your 915? I am hoping it was NOT SWEPCO, for once, because I would like you to change it again in a couple of weeks, but not to SWEPCO, yet. Then, in a month or so, change it again, but to SWEPCO 201, then I believe you will have a few months of reliable operation left in your 915, assuming you are reasonably careful with your shifting ... and I believe you will be!

What gears are you having trouble getting into, smoothly, at this point? Did you notice the shifting getting better with the new gear oil in it?

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Warren Hall
1973 911S Targa

I agree that you can get mor emiles out of your tranny before you NEED to do something. I also agree you can do all or some of the work yourself and save $$$. I know you have had good luck with Vertex, but I am some others have not.

Once the tranny is out, an exprienced rebuilder (EXPERIENCED PORSCHE TRANNY REBUILDER) could rebuild it in no time (couple of hours, max, plus parts). Parts can be a few bucks.

I also agree that this would be a good time to consider a spare tranny. Gosh, if you could get an older one cheaply that still works, you could bolt it in and drive it a bit to see if you like the shorter gearing. I would love to do so, because I rarely (never) go 140mph and I do believe that this would probably be the most fun, most noticeable single upgrade that could be done to my car. Period.

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'83 SC

Thanks for all the advice guys. It is the biggest relief in the world to ask an honest question and get an honest answer. I don't have to worry about any of you trying to sway me one way or the other because there is nothing in it for you.
I do trust the guy I take my car to...and I know if I have him do it he will do a quality job. I am just trying to weigh my options and decide what route is best. I have to look at the cost issue as well.
Like I said, the gearbox has always been quirky, especially 1st, 2nd, and reverse...I was just hoping that the problem was in my linkage of clutch cable.
Warren, I think my mechanic uses Valvoline oils in both engine and tranny. Whats the deal with the Swepco 201? I have heard it discussed before but what is the difference?
I might be able to try what you suggest but I would need some sort of pump to change the oil. Do you know an easier way?
And sure I would love do have a gearbox with a little more umph at lower speeds but I don't think I could afford such a modification.

One last thought...do you suppose that if I decided on a rebuild that I could save a bit of money by removing the tranny and just taking it into the shop for a rebuild and save on some labor?


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Leland Pate

___79 SC Targa

Lee, My assumption is that you could save something in the $350-$600 range by doing your own R&R, well worth the effort! That was why I suggested it.

The deal with SWEPCO 201 gear oil is that it is, very simply, the BEST lubricant for Porsche transaxles that can be found on the PLANET!!! Bruce Anderson found out back in the late '70's and early '80's that 935 race car ring & pinion gearsets would only last one or two races with conventional gear oils, but they lasted for an entire racing season when SWEPCO 201 was used in their transaxles!!! It also makes a much 'smoother' shifting 915, you will have to experience the difference to believe it, but it REALLY IS that much better! So, go ahead and change the Valvoline gear oil one more time (to be SURE all of those flakes and chunks of brass and steel are flushed out of your 915, giving the SWEPCO the cleanest possible environment to do its' magic) while you order the SWEPCO. Doesn't the base you are at have an auto 'hobby shop' where you can sign-up for a work space? They probably already have an oil suction gun, but if they don't, any major autoparts store should have one for $7-$12.

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Warren Hall
1973 911S Targa

Warren,

Can I use the Swepco 201 in a 901 transmission and hope for the same results.
My gears crunch when going from 1st to 2nd gear and I was thinking of trying what you have suggested in other posts to change the gear oil twice using Swepco on the second change.

Thanks,
nick
'70 911 E

Nick, I'm sure it is just as good on any of the Porsche transaxles back to the early/mid '50's, since they all use the same synchronizer/synchro hub/operating sleeve design. I would take a good, hard look at the gear oil you drain out the second time ... if it still has any visible flakes or particles in it when you let it settle in the bottom of a clean glass (pickle or other disposible) jar, then I think it would be best to put another fill of Valvoline or other low-cost gear oil before putting in the SWEPCO. The whole idea behind the 'cheap flush' is to clean out years of neglect ... if you have changed the gear oil before on an annual or regular basis, then one change should be fine, I just don't happen to like the idea of any leftover particles floating around in the SWEPCO to start with!

I have heard other people reporting the same good results in 901 and 914 transaxles with SWEPCO, but I don't have any personal experience with them.

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Warren Hall
1973 911S Targa

Warren, where is a good place to buy Swepco from? I saw it in Automotion but I don't want to pay $60.00 a gallon for it and I'm sure there is a more reasonable place to buy it from.
Any ideas?


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Leland Pate

___79 SC Targa

Recently, I've gotten my Swepco from Zims in Bedford, TX ...
www.***********



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Warren Hall
1973 911S Targa

I think (not sure) that PP sold me a gallon of SWEPCO 201 for $40. I don't think it gets cheaper than that. I got my pump (screws conveniently into the SWEPCO jug) at Harbor Freight Tools, but any auto parts store shoudl have them.

You might be able to get a front valance for what you save on the R&R, if you do it yourself. If I weren't so busy I'd consider driving down and helping. You can do this, you probably have time to think and plan, and you might consider a "spare" tranny.

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'83 SC

Hi guys,

I'm new to 911 ownership, and I've been lurking here for a few weeks now. I recently got my motivation up to change my trans oil, but when I got under the car I discovered that I did not have the right tool to remove the two plugs.

The plugs on my '85 Carrera have a *female* hex opening. I assume it's 19mm as is detailed in various posts here. My toolkit does not have a *male* socket (they're all standard females), and the local auto store (Carquest) expressed dismay at the diameter; they had smaller male hex sockets, but nothing that size.

Is my Porsche toolkit supposed to have this puppy? Did anyone else have trouble getting it? I assume not, since that's never mentioned.

FWIW, my 1st gear synchro is flaky, but I have learned to manage it. The biggest problem with shifting is a balky 2nd gear. It can be quite resistant, particularly on an upshift (not much fun).

Thanks for the replies! I am very favorably impressed by the quality discourse on this forum.

Roger

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'85 Carrera 3.2 coupe
Guards Red/Black Leather

Some times it is possible to use a 2-3 inch long bolt (where the head of the bolt fits the plug head) , a couple of nuts that fit the bolt and a standard hex socket or a wrench.

First put a nut on the bolt, then the second one also. Back the first nut off until it jams into the second nut (real snug) that you put on.

Second use the head of the bolt to fit in the female section of the plug that you want to take off. Use a wrench to turn the nut that is closest to the head of the bolt head in the "off" mode. As you take it off the threads will jam more. When putting the plug back in "on" use the outer nut as the driver for the same reason (threads jam).

Don't tighten the plug too tight.

s

I checked with the local parts stores and none of them have a pump that would work for my gearbox. Does anyone know a place that I could find a pump that would work well for swapping oil?

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Leland Pate

___79 SC Targa

I checked with the local parts stores and none of them have a pump that would work for my gearbox. Does anyone know a place that I could find a pump that would work well for swapping oil?

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Leland Pate

___79 SC Targa

Any auto parts store should have one. It's just a screw-top that fits into your jug of gear oil, and a plastic plunger-type hand pump and a few feet of flexible tubing. I got one in Kokomo Indiana a few weeks ago for something like seven bucks.

If you can't find one, and have a little time, let me know. I'll send you mine.

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Jack Olsen
1973 911 T sunroof coupe

Try a hardware store, Home Depot, etc.