Moving on with the intermediate shaft teardown, inspect, and rebuild, part C...
Measured the 0 gear with two 4.5mm pin gauges. Came in at 136.97mm and the minimum spec is 136.5mm. On to the next step...
Installed new Porsche intermediate shaft bearings. End play came in 0.042mm and the minimum spec is 0.040mm. On to the next step...
Prepared the shaft with some studs to guide lining up the holes...
Heated the gear in my thrift store bearing and gear heater (AKA toaster oven)...
After assembly (no pics), installed the intermediate shaft and crankshaft to measure backlash. Came in at about 0.135mm (ignore the rev counter) and the maximum spec is 0.049mm. Argh! Not on to the next step!
I was taught by the "old timers" to always change gears in pairs and the Porsche Technical Specifications booklet says to "replace intermediate shaft gears and crankshaft gears in sets only." Off to order a new 0 gear for the intermediate shaft and a new 0 gear for the crankshaft.