Rear wheels locked, diff problem?

[faiz]

Hi guys,

I need some help desperately.
On saturday night I was driving my '84 3.2, slowed down to about 30kph and was cruising and then all of a sudden the car came to a skidding stop.

I looked over the car and there appeared to be nothing wrong.
I started the car and tried to put it in gear but it doesn't go into any gears.
When I release the clutch it dies.

We tried to push it off the road but it can't be pushed, it just rocks back and forth proving that the brakes have not locked.

Had to get a car carrier to get it back home with the rear wheels still locked.

Before I start doing anything I was wondering if anyone had any ideas on what the problem could be?

As you can imagine I'm pretty worried as I live in Uganda, this is the only 911 here so any problem is way worse as I can't get a single part locally.

Just hoping it's not going to destroy my wallet.

[Porboynz]

It is possible to engage 2 gears at the same time and lock a gearbox, but if you were cruising as you say and not upshifting or downshifting this is unlikely. Any other cause is going to be expensive. There are posts on the gear selection problem.

[faiz]

Ok, had a look at this;

Locked wheels

Gave me some ideas.

I was in third gear if I remember correctly and funnily enough I remember struggling to find the gear at the time.
I'm not sure but I might've been shifting to second or maybe about to.
It all happened so fast and I was so bewildered by the whole thing that I don't really remember the events prior.

I just remember struggling to stay straight, thinking it was a blow out but afterwards I saw both skid marks.

btw this was at 1.30 in the morning on my way home from a friends house, it took 4 hours to get home after finding a car carrier. Worst night ever.

[faiz]

Originally Posted by Porboynz

It is possible to engage 2 gears at the same time and lock a gearbox, but if you were cruising as you say and not upshifting or downshifting this is unlikely. Any other cause is going to be expensive. There are posts on the gear selection problem.

Going to have a look at this and hope for the best.
Thanks for the response, Mechanics coming today to get started.
Unfortunately I have to work but I think some of the prior posts on here will be invaluable to us.

[Porboynz]

If you can still move the shift lever in the normal H pattern and reverse etc I suggest you do this repeatedly and if you are lucky you will knock it out of the 2 gears selected situation. Here is a post from John Walker with more info for your mechanic if you are not up for removing the cover plate from the trans yourself:

"remove that cover and pop the two shift rods into the neutral position. that would be when the notches are next to each other. if it remains in a gear, but now at least turns over, then it will be in 5th or reverse. if reverse, remove the backup switch and push the pin in until it goes into neutral. if 5th, the end of the shift rod can be seen in the edge of the access hole. pop it toward the end of the trans to get neutral on that rod. it should turn now, unless it's frozen from lack of lubrication"

There are lots of posts on 915 gearboxes stuck in 2 gears at once, spend a bit of quality work time cruising the forum and you will become the Ugandan expert on the subject, maybe even the entire African sub continent expert! Imagine! Good luck fella.

[faiz]

Lol I look forward to becoming said 'expert'!haha

Unfortunately I cannot move the gear lever into any gear.

It just seems to be stuck in the neutral position and I cannot put it into any gear.
I can move it towards gears, any of them, but it will not engage a gear.

I'm about to drain the oil to see what comes out and check the shift rods.

I'll post my findings soon.

Hope I get this fixed as the Uganda classic car show is on the 15th and this will be the first 911 to enter.
Would suck if it doesn't make it.

[Porboynz]

I would imagine that if it is in reverse then the reversing lights will be on, but you would have noticed that at 1.30am?

[faiz]

No reverse lights I'm afraid.

So I had a bit more a waggle with the gear lever and it does go into 3/5th.
I'm not sure if its 3rd or 5th or a mixture of the 2.
Thats the only place it slots into.

The mechanic removed the gearbox oil plug and plate and the oil was clean with no metal.

I need to have a look at the shift rods next.

Diff is fine, wheels are turning in opposite directions.

[faiz]

Well I discovered the problem/problems.

This is what I was hoping to see;



This is what I saw;



Totally messed.

Any ideas?

I'm gonna have to drop the gearbox and rebuild it.
What a pain in the a**!
I'm gonna have to drop the gearbox and find out all the parts required and then bring them from england.

So bummed out about this.
No classic car show for me this year as the Karmann is in the bodyshop.

Have you guys ever experienced this before?

[euro911sc]

ewww.... that's a complete disintegration of a selection gear. That big chunk out of place is a syncho band. That seems really odd to blow up just driving down the street. It must be in multiple pieces. I'm surprised you didn't break the main shaft either!

Yup, pull the box and begin your journey... sorry

[Matt Monson]

Yep, see it more often that most people around here think. What happened is the circlip that holds the synchro onto the gear let the synchro out. Sometimes you get away with minimal damage. Sometimes the pieces go through several gears, destroying them. Won't know until you get it apart.

Regards,

Matt

[john walker's workshop]

or the teeth broke off the dog tooth ring and the syncro stuff exited and left the snap ring in place.

[faiz]

Thanks guys.

I'll get started today, at least I'll get to have a good look at everything.

[Porboynz]

Sorry to see it was not the simple fix we were hoping for, keep us posted and best of luck with the dismantle.

[faiz]

Managed to pull the destroyed synchro band out, most of it anyway;

[/URL]

Putting the selector back in place and then going to try roll it into my garage slowly so I can drop everything.

[faiz]

Originally Posted by john walker's workshop

or the teeth broke off the dog tooth ring and the syncro stuff exited and left the snap ring in place.

Yup you got it.
Looks like the teeth on the 2nd gear dog tooth snapped off and one synchro ring came out.





Also broke the synchro guide sleeve unfortunately.
So annoying as it's such a minor break.



So it looks like I need to order those 3 parts and a gasket kit only.

Anyone have any advice on other parts to order?

Does Pelican do international shipping?
Want this back on the road pretty fast if possible.

[Jerome74911S]

I just telephoned Pelican on your behalf. Yes, they can ship to Uganda, no problem.

[faiz]

Originally Posted by Jerome74911S

I just telephoned Pelican on your behalf. Yes, they can ship to Uganda, no problem.

Wow thanks alot!

[faiz]

Hi guys,

So my mechanic rebuilt the gearbox and it still grinds.
It grinds going into second from first unless I pull it as hard left as possible, then sometimes it doesn't grind but again it takes a long time to slot it in.

From third to second it grinds no matter what.

This only seems to happen with second gear.

As you can imagine this is amazingly frustrating and has ruined the driving experience completely.
Do you guys have any ideas how I can fix this?
I tried adjusting the shaft position but tbh it hasn't made much improvement.
I might have another go and see if I can improve it via the shaft.

Any help and suggestions would be greatly appreciated.

[Porboynz]

Can you double clutch when down shifting 3rd to 2nd and get a smooth change? If so it sounds like a worn synchro problem, did you use all new replacement parts? Also its important after having a major like this to make sure all the selector rods and forks are still straight and true.