Van

Yeah, I'd think bearings, synchros, blockers, gaskets and seals are about it.

odurandina

I live 24 miles from Kevin Gross (straight up 495..... which is like having a direct line to God).... so......

odonnell

I wonder if replacing the r&p with more robust parts would be a good idea. I'm not sure if anything from the Audi cars of the era that used the 016 based trans would be worthwhile, but maybe a Passat or Boxster r&p swap? Only worthwhile if you have an NA trans to start from of course.

Van

The "pinion" is part of the gear-cluster shaft. I doubt it would be interchangeable from anything else. It's even different between turbo and NA and requires a different case (I seem to recall the turbo case is 4mm longer than the NA case).

drive135mph

such a cool thread

944crazy

Hi Eric, I'm reviving this thread because I am probably looking at rebuilding my gearbox. How did you go, and what tools did you end up buying?

Did you end up getting a 20t press and was it able to do the job? I noticed that supercheap and repco sometimes have good deals on their presses.

Van

I thought this would be a good thread to add this video.

944crazy

Awesome stuff Van, thank you very much. I love all your videos, they are always extremely informative.

If my 2nd gear on the input shaft is indeed mangled as I suspect, should I be sourcing a new shaft with a matching 1st and 2nd pinion gear to go with it? Or is it fine to just replace the input shaft itself, if there is no collateral damage elsewhere?

Van

I suspect it's not the actual gear teeth on the input shaft that are damaged (unless you had metal chunks wedge between the spinning gears), but rather the synchro teeth on the free-spinning 2nd gear.

And if that's the case, you can just put in a new gear (and synchro and blocker ring).

But, if the gear teeth on the input shaft are damaged, since they're machined in, you'll have to replace the whole shaft.

944crazy

The problem is I can't exactly remember if the damage happened during a shift, or as my boost came on. A sychnro can only be damaged during a shift right? I'm sure that I only did a 2nd gear pull, with no shifting involved...but I'm starting to doubt my memory...

If the sychro teeth were indeed damaged like you suspect, could it make a knocking sound similar to this when in gear?

http://s805.photobucket.com/user/tri...86418.mp4.html

I guess before I impulse buy a new gearbox I should check inside mine to see if it's not something relatively inexpensive like replacing the gear and synchro and blocker ring like you say.

Do I need any special tools to take the gearbox apart far enough to inspect for damage?

Van

Your link doesn't seem to work...

Remember, the driving force through the gear is transmitted to those little synchro ring teeth on the gear - then to the synchro ring, then to the output shaft.

For tools, you'll need a few snap ring pliers, and a press and/or puller to get the gear clusters off. Nothing too major.

944crazy

I've edited my comment with a new link that should work now.

I have all those tools apart from the press, am I right in thinking that I won't need the press just for an inspection? I just want to get a damage assessment for now before I decide on rebuilding my box, or buying a new one.

Van

I think you can get a pretty good idea of the wear without pulling the gear clusters apart.

FRporscheman

Van, great video, thanks for taking the time to make it!

Dave W.

A 12 ton press is sufficient to disassemble the gearsets.
I'd recommend at least taking off the end cover, 5th gear (gear puller or pulley puller needed), and the gearcase to inspect the gears. At that point you should see the damage so you'll know if it's worth repairing.