Part II: A guy in his garage attempts to install a LSD in an assembled G50 starts on page 6!
Hello Pelican, I am an average wrench and owner of an '87 911. I'm going to attempt to disassemble, inspect, and replace my 1/2 synchro rings and my 1-2 hub slider in my G50 transmission. I plan to document it all here on the forum to share with you all.
Why am I doing this?
The transmission isn't grinding currently, but it is difficult to shift into 1st when cold. It does loosen up a bit when warm, but is always tricky. To work around this I will double clutch or do the 2-1 shift to get it to drop into 1st. It sometimes still won't go easily.
So far I've:
1) Tried three different fluid changes including Mobil-1 and Swepco
2) Replaced the OE bushings in the OE shifter
3) Adjusted the OE shifter
4) Replaced the OE shifter with WEVO
5) Adjusted the WEVO shifter
6) Replaced clutch, slave, master, and pressure bled
No matter what I do, the symptoms seem the same and I expect them to get worse. The car has 150k on it. I'm sure it's been driven mostly lightly, but the clutch/slave/master had issues when I bought it 7 years ago, and it's not clear how long the issues were present. I'm certain the sychros have suffered over time because of this.
A new engine is going in the car and the trans is out. This is a great time to at least inspect.
How am I going to do this?
1) Well, I'm going to need help. Mostly from people like Dannobee, Matt Monson, and anyone else who has rebuilt a G50 and is willing to lead the blind. Anyone is welcome to contribute. I expect criticism
2) I have an engine stand and a yoke to mount the trans to. It feels pretty cantilevered on the case so I've propped in a 4x6 to support some of the weight. I've seen pro shops use similar setups so I 'think' I'm on right path. Things will get better as trans weight goes down. I'll get a furniture dolly as well as that seems to be a jig of choice to move parts around and rebuild this thing in a vertical orientation.
3) I'm going to use manuals and the forum to get through this. I have the commonly available G64 manual that someone is kind enough to host online and a 87-89 911 Bentley.
4) I have an assortment of tools, but I'm sure I'm going to need more. I'll share what I buy and where I get it as I go. I'll probably keep a tally of parts and tools along the way. I have a garage, own a welder, a press, a vise, and have space to do the work.
5) I have an OK background in cars and working with my hands. I'm not a professional wrench. I'm a mechanical engineer who has studied and approved aerospace repairs for the past 15 years. Before engineering I was in the autobody trade and have been trained in refinishing and structural repair. I've restored a few Ford Galaxies, and a modified a bunch of hobby cars along the way. I've been tinkering for my whole life from legos, lincoln logs, bikes, and now cars. I do most of the repair and maintenance on the home fleet.
OK with the background explained, let the pain begin.
My 1/4 drive 0-80in-lb deflected beam torque wrench is coming so I can measure pinion preload. My first step is to open up the G64 manual and the Bentley to see where to begin.
Onward!
Edit after completion of project;
Semi-Specific Tools Used:
1) Engine/trans yoke
2) Engine stand
3) Sturdy bench vice
4) Hydraulic press
5) Torch
6) Toaster or oven (capable of 120C/250F)
7) HF ICON master puller set
8) 41mm socket
9) 29mm socket
10) Torque wrenches capable of 0-120ft-lbs