How to remove stuck gear from input shaft?
 

situation resolved thanks..

Unusual.

I suspect it may have been incorrectly installed somehow. I have never encountered this.

Is there any sign of Loctite?

The 1st gear set (3 pieces) and the input shaft/second gear set are expensive pieces. It is worth some serious effort to rescue the situation.

I would make a custom puller out of a commercial ‘bearing splitter’. The key will be to pull on the backside of the gear while pushing on the center of the shaft.

It is possible to remove the pinion shaft and associated gears. You can then remove the bearing retainer. This will give you more room to work.

With two close-fit parts of the same material (steel), heating doesn’t provide any differential expansion/contraction. The only way to have an effect is transient heating and cooling. You could get the entire assembly dry-ice-cold and then suddenly apply heat all around the gear while pulling.

A word of caution.
The most fragile place in a 901 transmission is the radius between the 1st gear splines and the surface for the inner race of the 4-point bearing. This is a common point of failure. It is also in the middle of your issue.

Best,
Grady

You say you've tried heat. Have you tried thoroughly soaking it with PB Blaster and letting it sit for a day?

Then you should be able to get a pair of prybars, one on either side for equalized force, under the edge of the gear and lever it off.

Thanks for the replies gentlemen.

I'll pass it on to the guy doing the work.

Much appreciated. ;)

heat the gear a bit and sweat some beeswax into the joint. works incredibly well on rusted fasteners too. good luck saving that mainshaft bearing. the brass separater tends to break.

I made up a puller for removing those gears.I bought a tie rod end puller and ground it down to fit under the gear. I been using it for over ten years and have not broken it. PLEASE DON'T beat on the shaft with a hammer trying to remove it

I've noticed that the 914 first gear is very difficult to remove most of the time, especially compared to the 911 gears. I had success by very carefully using a pair of flatblade screwdrivers to pry it off enough to use a gearpuller.

Thanks again for the input...SmileWavy

Did you get it off?

Matt,

It is at a guy's house where he and another guy are working on it. I have been forwarding these suggestions to him and praying to the Porsche gods that they'll figure it out. Otherwise I'll have to take it somewhere else.

Thanks.

problem solved - they just machined it off...

Thanks again for your help.