Project 5 speed manual transmission repair: 928 78 mod

[palaur]

I have Begun to remove the transmission to make a repair. The idea was to replace the sync rings and sleeves, some of the bearings, seals and so on.
But discovered that shown in picture that this is somewhat more expensive than estimated first. :eek

I will post pictures of the repair eventually.

Discovered that it was broken (5 gear) (heavy on the $$$$$)



03 transmission with lim slip diff



Here are some pictures with the new repaired engine 4.7 l and painted engine room and hood





the car is now on the support, and is prepared to remove the rear axle



Here is the old registration number, its a bit funny to have on my wall as a reminder of where the car was used.

[Sapientoni]

The 928 manual trans is the easiest in the world to disassemble. Just make a mental note of the pre-selector springs. Usually the first and second gear synchros are the worst, but it was cheaper to buy a whole set (in 1991) change them all, and have no worries. Finding a gear, another story, never had to do that.

[palaur]

I hope that it is an easy task as you describe, post pictures as I go along.
purchased parts on Friday, 500usd for a shaft used. And sync rings,replace shifter and gasket sets. 1000usd for everything. 928international.
Today i
Removed the exhaust system, battery tray, brake, hand brake cable, drive shafts, stabilizer, released shifter, output shaft, shock absorbers. Tomorrow I'll remove the rear axle and gearbox.

[Danglerb]

Wow, its really rare that an early 5 spd only needs a thousand in parts.

[palaur]

have not mentioned the main bearing yet. Hope that it is ok but i wil change it if its worn, offfffcorse. 600+1000
http://www.molde-jarnvare.no/

[Pete R]

Norway... New Hampshire. I have a snowblower next to my 928 right now too

[palaur]

[palaur]

Originally Posted by Pete R

Norway... New Hampshire. I have a snowblower next to my 928 right now too

yepp, nice -10c and snow outside:::::

[MPDano]

Oh yeah! This is what I gotta do soon enough. Thanks for the pics. What are those parts in the last pic?

[palaur]

its the broken shaft from transmission, 5 gear shaft.. it was pulverized before i removed the transmission, look at the first picture in the thread. 1200 to 1500 usd to bye a new one but i bought a used one from 928 int at 500 usd...

[MPDano]

Oh, got it. That second to last pic looked like some sort of distorted seal. I see not that's where the pieces belong.

[palaur]

not a sharp image and a poor explanation from me about this and that my English is through google translator. he he

[palaur]

[Sapientoni]

You can usually identify a bearing and get them from an industrial supply house. Only "proprietary" items like the timing belt idler bearing with the special pulley integration, or odd sized (for proprietary reasons) inner or outer diameters have to be bought from a dealer.

Best of luck to you on this project. Remember the preselector stuff.

[palaur]

Originally Posted by Sapientoni

You can usually identify a bearing and get them from an industrial supply house. Only "proprietary" items like the timing belt idler bearing with the special pulley integration, or odd sized (for proprietary reasons) inner or outer diameters have to be bought from a dealer.

Best of luck to you on this project. Remember the preselector stuff.

Im not shure but is it this one that is the pre-selector spring?

[palaur]

I'll check with a local hardware store if they have bearings to my transmission.like this one:
Molde Jarnvareforretning AS - Home

[Danglerb]

Long thread (good luck Google translator) about bearings that fit.
Bearing madness - Rennlist Discussion Forums

[MPDano]

If you have access to a Bearing only seller like I do. Kaman Bearings in San Diego. You can bring on your old one and they just measure and match if the numbers on the bearing aren't there. The Torque Tube Bearings they matched, the Torque Converter Cover Bearings has numbers on them. Just another option besides what Mike posted.

[palaur]

Then the parts have arrived from 928 int jippi. The old parts that i have taken out of my transmission: I see that the main transmission cube was changed in 1998 ( it was engraved on the cube and bearing) also my old and broken 5 gear was actually changed in 2008 ( engraved ) I noticed that the torque tube shaft is a bit worn at the end, is actually a little slack when I try the new 5th gear on, do you think it matter?



conclusion: the transmission has been repaired erlier in 1998 and 2008

[palaur]

a rebuild torque tube ordered from 928 int today when the old one had faulty splines...