Transmission disassembly problem
 

I'm going through a 944 S2 transmission and am having difficulty removing fifth gear from the output (pinion) shaft. I believe this step is the same for all 944 transmissions. The factory manual calls for using a gear puller made by Kukko (which I just ordered, but hasn't yet arrived). Meanwhile, I've tried traditional gear pullers, as well as heat, and I can't get the gear to budge. The gear is splined to the shaft, which makes me think it shouldn't require all that much force to remove, but that appears not to be the case.

Here's my current puller setup, which involved cobbling together a couple of Harbor Freight pullers, and grinding the ears thinner so they would fit behind the gear. Not pretty, but I can get quite a bit of force with it. I'm concerned that even the Kukko puller may not work.

Has anyone ever done this before? Any suggestions or tricks?


http://forums.pelicanparts.com/uploa...1207612409.jpg

It should go without too much of a resistance... I did one on S2 and two on non-S 944, but had to use a slightly bigger puller. What are you planning to do with the transmission or are you just replacing the 5th gear? I think I have a photo saved somewhere I'll post if I find.

Mine just slid out with no resistance. It was splined so it should just slide out.

http://forums.pelicanparts.com/uploa...1207870331.jpg

Thanks for the responses, guys. I was beginning to think that no one had ever done this before!

Fifth gear definitely isn't just sliding off. I expected it should do so too, but it's really stuck. I'll try with the new Kukko puller that's on order and I'll report back with the results. I'm hoping that will do the trick.

My goal is to replace a cracked 3rd gear synchro, so the next step is to remove the input shaft and pull off the gears on that shaft. I have large snap ring pliers and a press. I'm hoping that's all I'll need (in the way of facilities and tools) to do this job. True?

I realize that there are a number of measurements that need to be made during reassembly to verify gaps and clearances. And it seems they're adjusted by purchasing snap rings of different thicknesses. I'm hoping that I can get away with just reassembling what I've taken apart (and that I won't need any new snap rings), but I plan to check it as I go.

Are there any "gotchas" that I ought to be aware of?

I've heard sharp hammering on the forcing screw of the puller, once it's tightened down as hard as you can get it, can help jar stuck things loose. Just don't hit it so hard as to damage bearings, or deform anything important. I've never actually had to try it with my limited experience with things that needed a puller to get off.

Thanks for the responses, guys. I was beginning to think that no one had ever done this before!

Fifth gear definitely isn't just sliding off. I expected it should do so too, but it's really stuck. I'll try with the new Kukko puller that's on order and I'll report back with the results. I'm hoping that will do the trick.

Try heating the gear evenly with a propane torch. I hate hammering the puller and transfering the impact on the taper roller bearings.

My goal is to replace a cracked 3rd gear synchro, so the next step is to remove the input shaft and pull off the gears on that shaft. I have large snap ring pliers and a press. I'm hoping that's all I'll need (in the way of facilities and tools) to do this job. True?

A press will be very handy. Just take note of the detents on the shift rods and don't loose them.

I realize that there are a number of measurements that need to be made during reassembly to verify gaps and clearances. And it seems they're adjusted by purchasing snap rings of different thicknesses. I'm hoping that I can get away with just reassembling what I've taken apart (and that I won't need any new snap rings), but I plan to check it as I go.

You can reuse tha lock rings, but it's a good idea to measure. Do you have the transmission shop manual?

Are there any "gotchas" that I ought to be aware of?

http://forums.pelicanparts.com/uploa...1208036504.jpg

As I can remember I got this puller from Pep-Boys... and grinded the ends so it fits under the gear. Also I used about 30-40cm long pipe to turn the wrench.

There are couple of tricks while rebuilding the tranny, but if you are not replacing the pinion bearings or ring and pinion then it should be straight forward, otherwise you need a special tool VW385/1 which only few places, that work on 944, have. I found one in Warrington, PA, the dealership founded by a famous Porsche racer Al Holbert.