965 engine / gearbox separation

[paganrj]

It is my first time working on a '91 911 turbo. I am having trouble separating the engine from the gearbox on my 965. I will like to know if it is necessary to remove the release fork or if there is any other trick to do that. Any suggestions welcome...R

[930gt-40r]

Yes, you got to "Un pin" the release fork or else they wont come apart
The pin is right below/next to where the clutch slave cylinder is.

[930gt-40r]

Oh and to undo the pin- you got to take the 10mm headed bolt and pull the little piece of metal out- then remove the round plastic plug- then screw that 10mm headed bolt into the fork pivot pin and yank it out. When you pull the trans from the engine, the fork will fall so watch your toes.

[paganrj]

Thanks for your fast reply Kris!!!!

[930gt-40r]

No worries- hope it worked out.

[AFM744]

Ahh, fond remeniscence of the first time I had to do this on my '89 3.2. I had to grind down a M6 cap head to fit in my slide hammer for this procedure... and lost much of my thumb in the bench grinder. I live 1 mile from the ER, but it was a tough drive while bleeding and in shock.
There are two different fork bearing shells, one for the left side and one for the right. Someone had installed them backwards on the Carrera so I had to drill out the bearing shell.
Words of experience; try to have both the engine and tranny well balanced during the separation so neither tips when they are separating. Straightening the case studs is a pain, and the G50 is heavy when it falls on a toe.
PM me on the trick to putting it all back together when you get there, I just did this last month and can walk you through it.

[lucittm]

Jon,
Sorry, but I just had to smile reading your post, ouch!

rj,
When you tug on the throw-out bearing fork shaft remember that you are only pulling against two aluminum bearing supports. If one of them snap off, you will be quite unhappy. Go slow.

Send us some pictures...

Mark

[AFM744]

To add to Mark's wisdom, PB Blaster is your friend. The pivot shaft is a tight fit through the throwout fork and may have corroded. I would spray it down preemptively.

EDIT: And be careful about the bearings as you extract the pivot shaft. My bearing rollers scattered to the four winds when I pulled my pivot. The replacement bearings aren't expensive, but they're a pain to find in the PET and a pain to install. If you find you have the "UPDATED" plastic bushings then you won't have this problem.

[A930Rocket]

Wow! I thought the four speed tranny was a PITA, but it sound like you guys have us beat!

[paganrj]

Just want to share how I put back the G50 and the release fork so that other beginners like me can benefit.

Here is the procedure I followed:
1-Clean all the parts and make sure the pivot shaft will go trough the fork without major resistance
2-Install inner pivot fork bearing
3-Place the gearbox on a creeper cart and level it
4-Place two jacks under the engine and level it
5-Attach the release fork inside the bell housing temporarily with a wire
6-Once the input shaft was inside the pressure plate positioned the release fork over the trow-out bearing.
7-Push the gearbox further until the fork holes are almost aligned with the gearbox holes.
8-While holding the fork in place remove the temp wire
9-Install the pivot shaft
10-Install the outer bearing, plastic cap and holder
11-Bolt and torque the gearbox to the engine.

Hopefully this will help others in the future............R