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Found my noise!
Gear lash noise under load + gear lever in 2nd moving backward under load pointed me to output shaft walking. Well, I was right......
Pulled motor/trans and first pulled side cover and diff. I caught it right in time as the R&P are still in perfect shape, but there was about 2 MM of for/aft axial play on output shaft. Further dissassembly showed why. 4 point bearing had axial play as well a trashed inner race (on the pinion side). The bearing retainer and pinion shims were beat to hell, and the roller bearing race was spun in the case. The good news was that the rest of the trans was in great shape! All teeth present and accounted for! Plenty of friction material on synchro bands. Out she comes! First time drop. Did it in just under 4 hrs by myself! http://i906.photobucket.com/albums/a.../engineout.jpg 4 point bearing race http://i906.photobucket.com/albums/a...earingrace.jpg Shims beat to hell http://i906.photobucket.com/albums/a...inionshims.jpg Beat up retainier http://i906.photobucket.com/albums/a...ngretainer.jpg This surface should be flat. Look at the trough that had been beat into the retainer by the bearing http://i906.photobucket.com/albums/a...niertrough.jpg Rest of the guts http://i906.photobucket.com/albums/a...rannyparts.jpg |
A lot of times the bearing race is loose in the case. I *think* that bearing is supposed to be a slight press fit. They seem to pound out the case and get loose. Could you spin the bearing race easily in the case with your fingers?
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Recommend the WEVO bearing retaining support. Welcome to Windrush Evolutions - WEVO - Porsche Products
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a wevo tensioning plate is a wonderful thing.
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You don't have a jeep, do you?
regards, Phil |
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When I did my repair, Aase Brothers cut the bad section out, pressed in another with a new bearing shell, added the WEVO retainer and it's been great for 5+ years.
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Is some slack/rocking normal in the 901? There are no noises at all in any gear and she shifts OK (as good as this trans can) after I added the new shifter and coupling. Right now I have RedLine NS gear oil in there but I'm thinking of making a change to Swepco or Kendall to see if the shifting can get even better. |
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Good luck....I just hope you don't have to pull it apart down the road...again.
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She made it almost 100k miles without the single bearing retainer, I think she'll go a little longer. Would be nice insurance though.
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Well, yes....but now it's a repair with a dimple to keep the bearing shell from coming loose again.
And to be fair, my failure was after a 3.6 install and hard launches in a couple of seasons of hard DE and AX use. The bearing got loose and took out second gear. It was a PITA and I sure don't want to consider doing it again. I had an assist from a friend and even better sources for the machine and parts...... So....the plate install is pretty straight forward....bolt in w/o mods. The plate is stock in the 930 trans. I just think it's good insurance for a couple of hundred bucks. |
So once the new 4 point bearing arrived I did a test fit into the used replacement bearing retainerr and the fit was recessed rather than flush or proud of the retainer. I went ahead and did a test mount of the bearing with the retainer and shims on the cases without the shaft in place and it was not good. Way too much slop in both radial and axial planes. Not going to work!
So I took the advice of JW and Joe Bob and went with the single bearing retainer from CMS. It's a very nice piece of hardware! http://i906.photobucket.com/albums/a...r/IMG_2618.jpg So now that the mainshaft has to come apart, some tool fabrication was in order. I took a page from Jim Sims book and welded the smallest 1/2" drive socket I had as a spare and welded it onto a 1 5/8" socket. I had to cut down the 1" drive 1 /5/8" and bored out the center with a torch to slip over the shaft. Gutted the old clutch disc to hold the the mainshaft at the splines which fits perfectly in the jaws of the vice. Supported everything with a pipe fitters tripod. It all worked great! http://i906.photobucket.com/albums/a...r/IMG_5207.jpg http://i906.photobucket.com/albums/a...r/IMG_2926.jpg http://i906.photobucket.com/albums/a...r/IMG_1474.jpg I got the gear stacks reassembled with the one piece retainer in place. I found it easier to do the pinion shaft first, then ziptie the two gear cluster togeher in two places (didn't take a picture), then press on the mainshaft 4 point and roller bearing. I couldn't find any threads on how others had done this with the single piece retainer, but this method worked for me. I then mounted the shafts and gear clusters into the case with the replacement shims. http://i906.photobucket.com/albums/a...r/IMG_7123.jpg This is as far as I've gotten with the tranny while awaiting the shift fork jig, which is taking painfully long to get shipped. In the meantime, I've spent a majority of the time cleaning the engine and all the other parts. Sodium hydroxide works great for this! http://i906.photobucket.com/albums/a...ncleaner-1.jpg After some spit and polish, paint, and a bunch of new seals and gaskets for the engine and CIS, the engine is anxious to return to duty! Still awaiting the new plug wires and clutch alignment tool to finish. http://i906.photobucket.com/albums/a.../engine1-1.jpg With tins http://i906.photobucket.com/albums/a...r/IMG_1287.jpg I've been agonizing not being able to drive my car. It's only been about 6 weeks since I stopped driving it due to the tranny issue, but it's downright painfull. I don't see how some of you can put these cars away for the winter or only bring them out on nice sunny days! Thanks again to all the Pelicans that have travelled into this territory before and left many great threads to learn from and those that are always there to help steer in the right direction.SmileWavy |
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