team illuminata

Took the engine and transmission out. Time to fix the transmission.












So, what do I do now?

team illuminata

Gearbox came apart quite nicely. No horror stories so far. Just a broken synchro ring and stripped dog teeth. The great news is the main bearing races are not loose in the diff housing and no gears look chewed up. I think we will be rebuilding this one

team illuminata

team illuminata

I made a closer inspection of the gear sets today. Looks like 1st on the main shaft is worn pretty bad. How do we fix that? The rest of them look OK, to me. Are they?











I also got the diff out. Looks like he only issue in there is a missing magnet pick for the speedo ring. Repairable?














I won't get till work on it again till next year but I'm not sure what to do next anyway.

team illuminata

Happy New Year everyone. Feels like I've been away from the car for a month yet it's less than a week. Strange.

Tonight I got to look more closely at first gear on the main shaft. I'm concerned this might be worn. What do you think? Doesn't photograph well though.






Then I got to disassemble the pinion shaft.




I gave everything a quick once over and found a few issues. Here's one obvious problem. I don't think that ring is supposed to be around the dog teeth like that and those bent bits used to be inside it!



I'll post more issues tomorrow if I get chance.

team illuminata

Today I did more research, separated the syncros on 1st and 2nd, inspected the rest of the components and drew up a parts list.

The first thing I have decided today is that 1st gear is not worn out. I don't think it is pristine but at $2500 it better fall out of the car and onto the road if it wants replacing. I looked at pictures on line of others and they do look very similar so it stays. Get used to it.

So I managed to disassemble the syncro rings on 1st and 2nd. Those snap rings are pretty tough. You can see the carnage on 1st, 2nd doesn't look too bad.







I'm going to replace everything associated with these two gears, except the gears themselves. I just need a tool to get the dog teeth rings off.


I then looked over the main shaft gears. I've decided to leave these alone as, in my opinion they look pretty good and I've never had any issues shifting 3 to 5,





So here is the parts list so far. Did I miss anything?

1st gear brake band (37)
1st gear dog teeth
1st gear synchro ring (39)
1st/2nd shift hub (41)
1st/2nd shift sleeve (42)
2nd gear brake band (37)
2nd gear dog teeth
2nd gear synchro ring (39)
accelerator pivot bushing (13)
Main shaft lock nut
Pinion shaft lock nut
Transmission Cover O-Ring
Transmission Gasket Set
dog tooth ring tool

There's also a few engine pieces to replace and add a new cutch cable and helper spring. I still have to decide if I'm upgrading the clutch and whether or not to install an LSD. Running out of time not to mention money.

team illuminata

Parts have begun to show up

Kitty thought there was a bird in here.




Maybe one of these magnets will work in my speedo ring.




Still need Dog tooth rings before we can proceed. Due here tomorrow so a busy weekend ahead. I wonder if I can get the transmission all back together before Monday.

Scott at Team Harco

I am always up for a co-drive with you - Paul. Whatever it may be.

Thank you so much for letting me enjoy your fine machine with you. It really is the most fun car to drive that I have had a chance to try (that is saying a lot). I need one for myself.

What are your plans for Sno*Drift? Is that the goal after the transaxle is rebuilt?

team illuminata

Thanks Scott. It's been a pleasure to watch you kick my **** in it.

It should be ready for Sno*Drift where Paul F will drive it as Green Light again. He was expecting a zero slot but he does such a good job of bringing up the rear he got green lighted again. Not as good exposure for the car though

team illuminata

Removed the dog tooth rings from first and second with the Porsche took. Started to clean parts and reassemble the pinion shaft.








Hope to have the box back together tomorrow.

team illuminata

Got the new dogs pressed on at Auto Europe.






Beginning to look like a gearbox again.

team illuminata

I think it's safe to say this is now a gear box again.






I even put new bushings in the throttle link rod thingy.




Now I just need the new clutch kit to arrive.

race911

When I saw this thread back up at the top I thought maybe some of the 993 crowd I pointed in your direction off the Chris Harris video might have made their way here.

If you haven't seen it, it's a 997 Cup prepared for WRC RGT:
But it was nice to go down 915 rebuilding memory lane. Been probably 10 years now that I've had to do one. The 15 years prior, I'd say I did at least one a month..........

team illuminata

Thanks Ken. I saw it a couple of weeks ago but it was nice to revisit it.

Scott at Team Harco

Oh man! That is amazing. A lucky boy, indeed.

Richard Tuthill has rallied here in the US. It's a whole different world in Europe. That car would easily be a top 5 finisher (overall) here. In WRC it's probably slightly better than mid-pack. But what a great idea and so well executed.

So Paul - let me know when you want to convert your car to stage rally duty. You've got a lucky boy waiting...