reassembly of 915

[gamtart]

I'm in the process of reassembling my 915 transmission and have a few questions.
I have the gear stack installed and torqued to the case with the shift fork jig installed. I am finding that the main shaft is hard to turn. It seems that 1st gear on the pinion shaft and the gear it meshes with on the main shaft are binding. If I remove the jig and slightly lift the main shaft everything spins freely. Before I start putting the rest together I am wondering if this condition is normal until 5th is installed and properly torqued? Or have I screwed up along the way somewhere.
It may be worth mentioning that I have yet to install the differential, if that makes a difference.
Also would like to know the install depths of the differential side seals. I've installed the non cover side flush with the case. Not sure if the side cover side is the same.

Thanks in advance.

[Jon B]

The 915 transmission uses tool P265c to install output flange seals 2.0mm/.080" below the surface- see tool recess in photo below. Seal depth, though, is something you can vary to avoid a worn or corroded surface on the flange. As far as spinning shafts, if they're not supported by the midcase, torqued, or if the forks aren't holding the sleeves in neutral positions, then they might not spin freely.

[Peter Zimmermann]

Welcome to Red Line Porsche Wiki - Porsche Wiki

Scroll along the left side of page, locate "Page tags," then click on 915. Enjoy!

[john walker's workshop]

you should stack the rest of the parts on the pinion shaft and snug up the big nut on the end to pull everything together. then see if the binding is fixed. when i set up the shift forks, the jig goes on and then the rest of the pinion stuff on top of the jig and and snug the nut, or you can get a false adjustment.
you may also have a spacer shim out of position which will cause the back of one of the dog tooth rings to contact the side of a gear.

[Jon B]

Update to seal depth question: the Porsche catalog shows an additional flange seal tool, P265d, "as from 1984 models", though it doesn't specify to which model it applies, nor do my manuals mention it. Any ideas? It is not a G50 tool.