$6 Synchro Hub Removal Tool
 

Just came up with a nifty way to get those stubborn 915 synchro hubs off the gear with 2 muffler clamps and two 6" bolts. Took exactly 3 mins of firm hammering to get it off, no damage to gear or syncro hub. Check it out:
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TA-DAAA!!!

You are the man! I cut mine off with a zig wheel and it took a while on each one w/o hitting the gear (or a finger).

That was my plan 'B'.

For a dentist - you ain't half bad!!!!

Wait till my next wisdom tooth patient sees me comin' at him with two muffler clamps and a hammer...!

That was way cool. It's like...you are in the desert...miles from any garage...and you need to rebuild you 915 transmission...and all you can find are some muffler clamps and some big bolts...

Nice job! I want to rebuild my tranny later (it is out of the car) and I have a new tool to look forward to.:)

Only slightly more expensive but a bit more precise clamping force....

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=3979

LARGE BEARING SEPARATOR $19.99. Often On Sale at $12.99

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HEY! Harbour Freight stole MY idea!!! Whatever gets the job done. As long as we one-timers can avoid the $100 price tag for the Porsche tool. I saw a post somewhere where a Pelicanite used an old retainer circlip and two wrenches to support the synchro hub. It worked too, but kinda bent the wrenches and a circlip costs more than these tools. Cutting them off is always a fallback.
BTW Motorhead, what's it like in Niceville.... nice? :)
It's definitely winter here, ice 'n snow and all that.

OK, I tried this method with a very stubborn 1st 901 gear. No dice, I ended up busting off the lip of the expensive synchro hub.

The closest muffler clamp I could get was 58mm so I left the retaining ring on and put the clamp underneath the retaining ring. The first gear I tried this on worked OK. The second was stubborn and broke.

Now, the question is, how do I remove the synchro hub after busting the lip?

andy

Alas, I bought the proper tool!

Hi, Andy

See post 158, shows you how I removed the broken ring, felt a bit brutal when I was doing it but every thing turned out fine, no issues

http://forums.pelicanparts.com/porsche-911-technical-forum/744845-pendulum-outlaw-build-adventures-misadventures-8.html

Cheers, Tom

Do you guys think this method will damage the syncro hub? I have new hubs that were pressed on my 2nd and 3rd gears years ago by a local shop. Never installed. With age comes some wisdom (sometimes), and I've since decided that those gears should be replaced. So I need to take the brand new syncro hubs off without damage, so I can then press them onto the replacement gears.

I have a press, but I don't have the official tools. My plan was to go back to that same shop and have them do this for me.

Mark

I buy the proper tool, then resell it.

I stopped by a local porsche shop that rebuilds 915's. They pressed the old dog tooth gear off and the new one on for $20. They used a shop press and some other spacers and such.

Yeah, that's what I did before. My shop did it for free. I suspect they will do it again-they know if I get it running I'll be back.

Mark

It's on there so tight that I suspect I would have the same results as Tom even using the proper tool. This is a first so there's two opposing spaces where there is less material. I'm thinking of whacking it with a cold chisel on those flats until it cracks apart.

Thoughts?

andy

I've been told by the guy who makes the gears, you're better off cutting the synchro ring off to preserve the press fit that is designed into the male teeth on the gear. I've used & own the SIR P225 and P226 tools but i'd rather keep the press fit from being loosened up and instead cut the ring off.

When you go to install the new ring, heat it up in a toaster oven to 250°F to 300°F and freeze the gear. The new ring will drop right on to the gear.

It looks pretty tricky to cut it off without touching the gear itself, any tips?

andy

Cut it most of the way (in 2 separate locations) with a cutoff wheel & sever it with some strikes via hammer & chisel?

Nice thinking Dent!