Transmission Help

Matt Russell · 03-27-2001, 04:56 PM

Hey folks...
Well, because of a whine coming from my (the cars) rear end, i have changed the transaxle due to the fact that i had an extra one lying around. The 2nd Tranny has been in the car 6 weeks, and is now jammed in third gear. Fun Fun!

anyway... the Haynes manual doesn't have a procedure for tearing down and rebuilding a manual transaxle in these cars. i have had good luck with a VW transmission, and am told that the Tranny in a 944 is similar to that of an Audi 5000. so i think that i can do this job...

does anyone have access to, or could you tell me where to get a procedure for rebuilding a Manual Transaxle for an '84 944?

I'm going to rebuild the first one that i took out of the car, which i believe has a set of bad final drive bearings.

thanks, any help would be appreciated.

-Matt

1.2gees · 1.2gees's Garage

Yeah, they're in the factory workshop manuals.

You can get them from several sources. I believe I have two copies of the transaxle volume(s).

I'll look into it, let you know.
Ahmet

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It's all the driver...

kukunaokala · 03-27-2001, 05:42 PM

Make the guy an offer, Ahmet, might help pay for one or two spark plug wires.

A local 924-944 repair specialist offered to let me xerox his manuals. Imagine going to the bank and asking the teller, "Can I have a hundred dollars in nickels, pleeeease.", and with a straight face. Aloha, Neal

wolfrpi · 03-27-2001, 08:51 PM

go to kinkos

Matt Russell · 03-28-2001, 04:59 PM

Thanks for the words.
Please let me know...

If you're interested on the mess i'm in now... read on:

I actually started disassembling tonight. took the output shaft cup off, and the removed the one cover that i could... thus providing access to the Passenger-side (looking down at the tranny) bearing and race.

Got a bunch (10, i think) of German 5mm hex bolts, tight as heck, holding one side of the ring/pinion to something. who knows?

by the looks of it, i don't think the ring and pinion are bad, no tracks... just play in the bearing/race that sits on the ends.

also, doesn't look like there's any way to get that gear out of there without taking out the 1- input shaft from the motor side, and 2- the "final" drive shaft with a large rotary gear on it that comes FROM the transmiision part of the assembly.

Took about 10-14 bolts from the end cap, but that didn't seem to dislodge anything (it won't split apart).

I'm guessing that the forks are holding everything in, if so, it's gonna be a royal pain in the butt to disassemble.

That's probably where the 'trick' lies.

I've stopped for now, before i get myself in too deep. but if you've read this far...

Well, anyway...
Gotta go heat up the blowtorch and charge the compressor..

-Matt

kukunaokala · 03-28-2001, 05:22 PM

Check out the PARTS DIAGRAMS in the Pelican 944 section. It has assembly drawings, better than nothing. Either you've got guts (experience with trannys) or are nuts. Keep that blowtorch away from your car. Good luck and aloha, Neal

Kaos · 03-29-2001, 05:42 PM

Hey,

I just finished rebuilding my tranny about a month ago. My first trans rebuild ever, and it went pretty well. I have driven only 300 miles since the rebuild, and it hasn't blown up yet.

I used the factory microfiche that I bought from Pelican for $35. Much cheaper than the $300 set of manuals. I just go to the local library with a bunch of dimes and use their microfiche to print out the pertinent sections. Works for me!

I replaced all of the synchros, bearings, and the shifter detents. Total cost for parts from Pelican was about $400. I paid a local machine shop $60 to press off some of the old bearings and press on the new ones. You will still need a gear puller of your own to get everything apart. I think you need one with 7" long jaws.

You will need some loctite anaerobic sealant to put everything back together, as there is no gasket between the main shaft housing (steel) and the diff housing (aluminum).

Good Luck!

Kaos 1985/2

Matt Russell · 03-31-2001, 09:40 AM

Thanksfor the words Kaos,

Actually, just printed some exploded parts diagrams from the Pelican Web site, and the should help as well. Good idea on the Microfiche! have to look into that!

(perhaps i'll visit Kinko's yet!)

anyway, great. I've actually got some experience with another (VW) tranny, and they're just like a puzzle: gotta figure out which bolt to take out, before the next piece comes out.

Question though: do you have to dissasemble the entire Transaxle to take the ring and pinion out?

Cause all that i'm interested in replacing are the bearings/races that the ring gear sits in the case through.

Thanks for the words, ya'll...

Anyone else wanna tell me how nuts i am?

peace
-Matt

Quote:

Originally posted by Kaos:
Hey,

I just finished rebuilding my tranny about a month ago. My first trans rebuild ever, and it went pretty well. I have driven only 300 miles since the rebuild, and it hasn't blown up yet.

I used the factory microfiche that I bought from Pelican for $35. Much cheaper than the $300 set of manuals. I just go to the local library with a bunch of dimes and use their microfiche to print out the pertinent sections. Works for me!

I replaced all of the synchros, bearings, and the shifter detents. Total cost for parts from Pelican was about $400. I paid a local machine shop $60 to press off some of the old bearings and press on the new ones. You will still need a gear puller of your own to get everything apart. I think you need one with 7" long jaws.

You will need some loctite anaerobic sealant to put everything back together, as there is no gasket between the main shaft housing (steel) and the diff housing (aluminum).

Good Luck!

Kaos 1985/2

lm6y · 03-31-2001, 01:29 PM

You aren't nuts, just alot braver than most of us.

Kaos · 04-01-2001, 07:22 PM

You don't have to take out the individual gear shafts to get at the differential bearings. What you do need to do is remove the steel gearcase from the front (towards the front of the car) aluminum diff case. You can leave the rearmost aluminum end casing on the steel gear case. First you need to remove the gear selector. Just undo the multiple bolts that hold the steel gear casing to the diff housing and be prepared to beat it with a hammer. In addition to the bolts, there are two dowel pins holding it together. The manual says to punch out the dowel pins before removing the casing, but mine were rusted in there for good. Just beat it with a big ass hammer and some pry bars help as well. Have someone help you with this when you pull it off, as it is pretty heavy and is easier to pull off straight with assistance.

To get the bearing races out of the aluminum casing, I found a neat trick. When I was rebuilding my trans about a month ago it was pretty damn cold out here in Michigan. I have a small propane heater for work out in the garage. I just propped the aluminum housings up against the heater for 10 minutes, and the bearing races slid right when I held them upside down. Just get the new bearing race in before the aluminum casing cools down.

Kaos 1985/2

kukunaokala · 04-01-2001, 11:52 PM

Whenever I hear or see the word "hammer" I get this automatic reflex. It's like my hair raises or my skin starts to tingle. Actually it's from bad experiences. Aloha. Neal

1.2gees · 1.2gees's Garage

I'm gonna talk to a mechanic that I lent the manuals out to, I received half of an extra set.

I should know if I can get you the 3 volumes, (including the transaxle)by tonight.
Ahmet

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It's all the driver...

Matt Russell · 04-04-2001, 03:22 PM

Ahmet-thanks for checking on those books, but i'm going to forge ahead...

ordered the seal/gasket kit from Pelican today, along with the bearings. should arrive by saturday, and be back in the car by sometime next week.

I'll let you all know. I'm still checking the Board here frequently, so if you've any other words or advice...

Thanks for the help folks.

peace and a 944
-Matt

1.2gees · 1.2gees's Garage

Well, found out I've got an extra set.

Yes, including the full volume on the transaxle.

E-mail me if you want it.

Good luck to you either way, keep us updated I'd like to rebuild a transaxle the right way someday!
Ahmet

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It's all the driver...

Matt Russell · 04-07-2001, 07:10 AM

Will do.
Just dropped everything off at the machine shop today...

and spent several minutes helping someone under topic "951 Tranmission help".

print it out for future if you like.

drop me a line about a price Ahmet. and how much to ship?

peace
-Matt