Originally Posted by evan9eleven (Post 9799531)

Thanks Peter! I'll check my manuals.

The engine stand and benchtop press arrived today; I'll have a go at degreasing the beast tomorrow evening so I can hopefully start the teardown this weekend. I've decided to open it up before ordering parts, even though I plan to replace most of the major bits.

Speaking of parts I've been advised that when it comes to synchros that the original Porsche items are the only way to go, but that with bearings the equivalent FAG and Timken units are just fine. The head scratching really starts when there are two different aftermarket bearings to pick from our host. Like the mainshaft bearing 999.052.030.00. Besides the $224 P original version, there are two from FAG. One at $116 and one at $58. I'm more then happy to settle for one of the less expensive two given the manufacturer, but what makes the difference between those?

It gets even more confusing when the manufacturer is just "OE Supplier" or "OEM" or "IR Torrington" or something else. If anyone can enlighten me here, I'm happy for any tips I can get. SmileWavy

Originally Posted by kevingross (Post 9799592)

On the ring-to-pinion backlash, again follow what the manual says to get it within the specified range. You need not buy the factory tools. For years I used a simple home-made equivalent, picture below, that in fact works better than the factory tool when re-using differential carrier bearings. (And then I bought the factory tool, because of course he who dies with the most factory tools wins.) There are lines drawn on the angle iron stock at the nominal radius at which to measure free-play.

http://www.connact.com/~kgross/asset...ash 002 sm.jpg

Best of luck with the project, and keep smiling! Pete's wiki on 915 rebuild is fantastic and will see you through the project.

Originally Posted by Trackrash (Post 9799629)

There has been some recent discussion on dog teeth here. http://forums.pelicanparts.com/porsche-911-technical-forum/975481-need-replace-dog-teeth.html
IMO most of the time, OE is good. Only difference is Porsche has not actually touched it. Read about dog teeth, however.

Originally Posted by al lkosmal (Post 9799829)

Evan,
Good luck with the project. I know that there should be no shortage of frosty beverages in the man cave.

regards,
al

Originally Posted by Peter Zimmermann (Post 9800408)

Evan; here you go...

http://forums.pelicanparts.com/porsche-911-technical-forum/471002-915-p259-tool-measurement-request-pics.html?highlight=Tool+915+diff

I know that you'll see it in my Tutorial, but don't skim past Post #45!

Originally Posted by Trackrash (Post 9802256)

You don't need a locking tool for disassembly if you have an impact wrench. Just buzz off the two big nuts. You can either use a rag to jamb the gears or put it in two gears at once.
If you read this thread, he found a method to disassemble without loosening the shift forks on the rods.
file:///C:/Documents%20and%20Settings/Gordon/Desktop/Porsche/TrannyRebuild.htm

Originally Posted by evan9eleven (Post 9802265)

Thanks Gordon. I have two impact guns but only up to 24mm impact sockets. Thinking a standard socket probably has no business on an impact wrench. :D

I've seen Gordo and others reference not loosening the shift forks so I'll give that a go.

Your link didn't work btw.

Originally Posted by evan9eleven (Post 9797835)

Originally Posted by Brian911T (Post 9803733)

That sachs clutch disc looks like the newer verision that came out in 2012 with single springs and 10mm smaller inside diameter. Could help you figure out mileage if you have other receipts. I'm in the process of changing my clutch and here is a pic of the old style and new.

Originally Posted by evan9eleven (Post 9800250)

Kevin! Thats a mighty cool homemade backlash tool. Do you have more pictures, especially with it in use? I've ordered a dial gauge and am starting to get my head around the concept and procedure, but exact dial gauge placement and what variation of tool to make are still eluding me.

Originally Posted by Trackrash (Post 9804290)

OK, I'll chime in.

That fifth synchro band is toast. However, some mechanics will move a good used one in there with good results. I doubt you need a new 5-R slider, but you might want to check it carefully considering the condition of the synchro.

That 1st gear dog teeth set is showing wear, probably not worth trying to reuse it.

Check the inner bearing race on your 5th gear. Any lines, you will need to replace the gear.

That needle bearing looks great. Unless they show wear or damage, they can be reused.

That spider looks good, as do your brake bands.

That 1 - 2 slider is best replaced with the synchros.

Originally Posted by kevingross (Post 9805240)

Hi Evan, busy week, sorry for the delay. Here are a couple of pictures =snip=

I hope this is helpful.