915 going back together - questions and missing bits
 

I pulled the tranny in my '81 SC 2 years ago, and am finally almost ready to do the final reassembly... minus a couple details that I want to double check.

1) I'm missing the roll pin for the input shaft nut. I have searched a pile of threads here, and can't find the size. Anyone know off hand? Otherwise I'll buy a mittfull of them at the hardware store and see if any of them fit.

http://forums.pelicanparts.com/uploa...1449418469.jpg

2) the Bentley manual calls for 2-3mm clearance between the shift guides. It's an inexact measurement though, because the shift forks have some play on the operating sleeves... and that play is also present between these shift guides. So... does this look about right?
http://forums.pelicanparts.com/uploa...1449419988.jpg

http://forums.pelicanparts.com/uploa...1449419938.jpg

3) The detents in the gear housing... I think these are correctly positioned according to the Bentley. I can see the rounded tips of the detents in both holes. Does this look right?

http://forums.pelicanparts.com/uploa...1449420226.jpg

http://forums.pelicanparts.com/uploa...1449420263.jpg


Other than those issues, I think I'm ready for final clear and reassembly. I lost the pin for the reverse switch, but the consensus seems to be that a machined 5/32 drill bit (either 52 or 59mm) will do the trick.

Any other last minute bits of advice for a 1st timer's 915 rebuild?

The center housing detent is in the right place. How about the detent in the diff housing? Was it between the two shift rods?

Yes, the diff housing detents were pretty easy to figure out thanks to many threads here and many posts by you, so thanks. For whatever reason I just couldn't quite visualize the gear casing one, so I appreciate you confirming I have it right.

Do the shift guides look ok? I have 3mm there but wanted to make sure it looked ok. I have my shift forks centered properly.

I managed to find a 5/32 x 1" roll pin and that seems to be a perfect fit for the input shaft castle nut.

A couple more questions from a timid 1st timer:
- My syncro assemblies rattle if I shake them. That's normal, right?
- I read somewhere (I think) that when the outer rings get compressed inside the dog teeth, they should not want to pop back out befor the snapnring gets put on. If they want to pop, that indicates wear. Is that right? Because even on 1 & 2 with new teeth, they wanted to pop out.

I got a roll pin I can send you, pm your address, Merry Christmas.

I see problems in your assembly; please refer to my 915 Tutorial at: Porsche Wiki

1. Shift fork adjustment looks way off, see the guide for thorough instructions (Part #7 has your info).

2. Are the asymmetrical teeth on your 1/2 slider backwards?

3. 3rd gear dog teeth (hard to see); pressed against the gear?

4. Just curious, are there diff shims under your bearing clamping plates (also hard to see)?

Basically, I need more pictures...

jeeze why am I just seeing that wiki now, after 2 years of reading threads?? haha

I've gone over the clearance of the shift guides... I adjusted them since the picture was taken. I'm going to follow the wiki guide and test shift it with the whole thing dry assembled.

asymetrical teeth are pointed to first for sure

3rd & 4th syncro teeth didn't get touched, they're fully pressed on

yes, shims are there under bearing plates... they were in good shape

2mm with the shift guides squeezed together:
http://forums.pelicanparts.com/uploa...1449457480.jpg

3mm with them pulled apart
http://forums.pelicanparts.com/uploa...1449457519.jpg

at least I'm comfortable

http://forums.pelicanparts.com/uploa...1449457608.jpg

Gutsy. I would never get away with that in the living room

Must be a single guy because my wife would kill me for doing this in my living room.

Violating house rules.........
 

Yelcab,

When my wife went to Australia to visit her parents for six (6) weeks, I got the courage and opportunity to finish the engine rebuild in our kitchen. She hates the smell of oil and solvent. With her away, I was able to finish the project well ahead of schedule because normally I would procrastinate and delay things. With the engine cases and crankshaft, engine stand, etc. in the kitchen area, I was under pressure to get them out before she comes back home. Working outdoor in the winter is not very conducive. I don't have a garage just a two-car carport so you could imagine spending many hours during winter time wearing thermal underwear, ski pants, coat, bonnet, and gloves to keep warm.

With the new technology, it is difficult to hide our mischievousness. Last month, wife went to California to visit our eldest son's family for a month. Another great opportunity for me. I brought the CIS bench tester inside the kitchen to calibrate & test WUR and FD. When she called me using FaceTime, she wanted to look what's in her kitchen and I was caught red handed. I got the crime scene cleaned before she got back last Friday. And took her to dinner on Saturday. She knew I disobeyed her again........

Tony

I do have an enclosed garage with a lift, and decent space so I never had to do anything in the living room. I did make a mistake of using the kitchen oven to bake painted parts once and got yelled at. I bought a $25 used oven after that, and put it out side. It works.

hahah yeah, I'm single now.

Which came first, the chicken or the egg?