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Immature Member
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$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:
    TA-DAAA!!!
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1984 Carrera Coupe = love affair 1997 Eagle Talon Tsi = old girlfriend (RIP) 2014 Chrysler 300 AWD Hemi = family car "Lowering the bar with every post!" |
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11-17-2006, 05:07 PM
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Join Date: Oct 2003
Location: Mount Pleasant, South Carolina
Posts: 14,526
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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).
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11-17-2006, 05:19 PM
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That was my plan 'B'.
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1984 Carrera Coupe = love affair 1997 Eagle Talon Tsi = old girlfriend (RIP) 2014 Chrysler 300 AWD Hemi = family car "Lowering the bar with every post!" |
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11-17-2006, 05:21 PM
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Join Date: Apr 2002
Location: Cheraw, SC
Posts: 811
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For a dentist - you ain't half bad!!!!
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Brian Keith Smith |
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11-17-2006, 05:35 PM
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Wait till my next wisdom tooth patient sees me comin' at him with two muffler clamps and a hammer...!
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1984 Carrera Coupe = love affair 1997 Eagle Talon Tsi = old girlfriend (RIP) 2014 Chrysler 300 AWD Hemi = family car "Lowering the bar with every post!" |
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11-17-2006, 06:36 PM
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Join Date: Apr 2006
Location: Newcastle, WA
Posts: 966
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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. 
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James 1969 911E Slate Grey 1981 911SC Wine Red 1997 911C4S Ocean Blue |
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11-17-2006, 06:52 PM
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Join Date: Oct 2005
Location: Niceville Florida
Posts: 274
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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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11-18-2006, 03:29 AM
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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.
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1984 Carrera Coupe = love affair 1997 Eagle Talon Tsi = old girlfriend (RIP) 2014 Chrysler 300 AWD Hemi = family car "Lowering the bar with every post!" Last edited by dentist90; 11-18-2006 at 09:55 AM.. |
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11-18-2006, 09:51 AM
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Join Date: Feb 2005
Location: California
Posts: 724
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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 |
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07-07-2016, 02:40 AM
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Alas, I bought the proper tool!
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07-07-2016, 06:17 AM
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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 Pendulum Outlaw, Build, Adventures and Misadventures Cheers, Tom
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Outlaw .... by definition ..... does not follow rules well www.FloydDesign.ca https://www.youtube.com/watch?v=sV5aIALWlG8 |
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07-07-2016, 06:47 AM
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Join Date: Sep 2007
Location: Boston, MA
Posts: 1,480
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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
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1979 911SC Targa |
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07-07-2016, 06:53 AM
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Join Date: Oct 2001
Location: San Carlos, CA US
Posts: 5,550
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I buy the proper tool, then resell it.
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Porsche 2005 GT3, 2006 997S with bore-scoring Exotic: Ferrari F360F1 TDF, Ferrari 328 GTS Disposable Car: BMW 530xiT, 2008 Mini Cooper S Two-wheel art: Ducati 907IE, Ducati 851 |
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07-07-2016, 07:06 AM
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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.
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Lillie - 1979 911 SC Targa, The Original 911 SCWDP Car. Rebuilt and roaring to go! |
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07-07-2016, 11:47 AM
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Join Date: Sep 2007
Location: Boston, MA
Posts: 1,480
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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
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1979 911SC Targa |
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07-07-2016, 12:17 PM
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Join Date: Feb 2005
Location: California
Posts: 724
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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 |
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07-07-2016, 02:43 PM
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Schleprock
Join Date: Sep 2000
Location: Frankfort IL USA
Posts: 16,640
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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.
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Kevin L '86 Carrera "Larry" |
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07-07-2016, 03:13 PM
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Join Date: Feb 2005
Location: California
Posts: 724
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It looks pretty tricky to cut it off without touching the gear itself, any tips?
andy |
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07-07-2016, 04:16 PM
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Schleprock
Join Date: Sep 2000
Location: Frankfort IL USA
Posts: 16,640
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Cut it most of the way (in 2 separate locations) with a cutoff wheel & sever it with some strikes via hammer & chisel?
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Kevin L '86 Carrera "Larry" |
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07-07-2016, 05:40 PM
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Quote:
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Karl ~~~ Current: '80 Silver Targa w /'85 3.2. 964 cams, SSI, Dansk 2 in 1 out muf, custom fuel feed with spin on filter Prior: '77 Copper 924. '73 Black 914. '74 White Carrera. '79 Silver, Black, Anthracite 930s. |
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07-08-2016, 03:00 PM
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1984 Porsche Carrera
Eagle Talon TSi AWD
Chrysler 300 AWD Hemi
1969 Lotus 7S3
Lillie
1974 Carrera
1979 930
1980 SC Targa
