Tranny Tyranny

[red-beard]

Actually, the tranny is fine, it's the heat exchangers....

I'll put part 2 together with the next gear stack rebuild.

Part 3, putting it all back together -

Tranny is back in the car. I made a "trial run" on the in place tranny refurb. Not too bad. I installed my 6's tranny back into the car with only the differential installed. It's pretty weird, being the "jack" for the tranny. I went ahead and reconnected the CV joints and reinstalled the starter.



Well, this is what the "gut less" tranny looks like. I didn't take a shot of the gear stacks and inermediate plate going in, but I am rebuilding one more tranny and this one will be fully documented.

This is a tail shifting 6 (a 901/10!), and an early one. I'll take a shot of the differential cover. It still has the support built in for the clutch cable guide, a left over from the 911.

The gear stack slid in with little or no problem. One "trick" is to hengage 4th gear, which helps position the stack to slide in. I did have to turn the gears a little bit (kind of like putting in a distributor). Uh, a hammer helps. Seriously! You lightly tap the intermediate plate to move the gear stack in, the last inch or so. I found that the 2 dowel points to be good positions to tap.

Once the gear stack is in place, for a tail shifter, you need to make sure the shift slector rod is inserted in it's hole properly. Then tap the intermediate plate home.

The hard part: Putting the cover on. Make sure you've removed the speedo drive. Side shifter, it's a breeze. Reassemble reverse onto the reverse shaft. Keeping the cover tilter back a little bit (having the engine and tranny tilted down helps a little bit here. Slide the cover home and get the reserve shaft into it's home. The final "washer" on the reserve stack has to be aligned. Make sure it is in the correct position. Adjust it into the correct position with your fingers while the cover is about 1 inch from closure. Once everything is all set, tap it into place with the hammer (Damn thing sure comes in handy, but, don't get wild with it!)

For a tail shifter, it's a bit tougher. You have to do everything on your back! The shift selector fits into a recess in the tail of the cover. I expect this is where the 911 shift shaft used to go. You have to position it with your fingers from inside the cover, until it's in the correct place, all the while not letting reverse fall off.

When reverse falls over, yell a bit, curse and find the bits as they roll away. Clean 'em off and try again. Follow the rest of the directions as a side shifter.

Once the cover is on, I put a couple of nuts into place.

On the tail shifter, I put the support fork in. For a side shifter, install the gear selector console. Test out the gear selection with the external selector. Don't worry if it's a little stiff. If everything seems ok (being able to select each gear), then go ahead and close up the cover and torque the nuts. Be careful, they only need about 18-20 foot-lbs.

Reconnected the main shifting shaft. I checked the gear shift and made sure I could shift into every gear. All set, went ahead and reconnected the tranny ground strap and torque the bolts on the cover and the side access port.

Reinstall the gear selector cover. Re-install the muffler.

AND take it out for a spin!

OK, I still have a couple of nuts left on the passenger side heat exchanger. I'll let everyone know how it is tomorrow...

James

[Jim Smolka]

Interesting way of doing a tranny.

I am confused, what is reasoning behind rebuilding the tranny with it in the car???

Good shot of the gear box!

[red-beard]

Basically, my idea is to minimize the pain. If the seals are OK, and all you have is a couple of grinding gears, this is the way to yank the guts out of the tranny without messing with pulling the CV joints, Heat Exchangers or the entire engine. The tail access makes this possible.

Wayne wrote an article on how to repair 1st gear while leaving the tranny in the car. I'm basically expanding on this, since 2nd gear is also very likely to be bad.

The tenant of this is to be able to check and rebuild the synchros, sliders and dog teeth in 1 day.

One of the most important lessons I've learned in this excercise: Check your bearings!!!! 1/2 of the transmissions had at least a bad pinion bearing.



This is the shattered brass cage which holds one set of pinion ball bearings.

James