captainOCD

Just saw this part of your post now Greg. I'll have to check when I go back to get the parts. I meant to the other day, but forgot. I might end up buying the calipers and master off of it for the tan car.

captainOCD

I got the call that everything was pulled today. It's back home on my trailer now and I'm going to try and degrease things some before putting it in the garage. Haven't gone through all the small stuff yet, but it seems like everything important is there. The shift boot is the only obvious thing I see missing, but it wasn't on the car when I looked at it last week, so wasn't expecting that to be here.









The clutch looks like a new spec unit. I haven't taken it apart, but the guys there said it looks like it's never been used.






I also don't think I'll be in need of Carl's template for the clutch master with how much of the firewall they cut out for me (it's got a hood hinge attached).




Probably more pictures to come later once things are cleaned up a bit. I'm grinning ear to ear right now. I really think the 5 speed is going to transform the way this car feels (sorry Roger). I was kind of regretting not finding a 5 speed to begin with (granted I just bought something out of a field knowing nothing about Porsches at all), but hopefully this all works out now.

Bigfoot928

this is the link to the page I followed when I did my conversion.

https://web.archive.org/web/20050205...ch_linkage.htm

captainOCD

I did get the parts degackified a bit. I didn't see any identifiying marks on the trans (unless it's on the bottom). Sadly the diff is open. I'll have to double check once I separate the front input shaft (through the clutch) off the driveshaft since it might be rubbing against the guide tube, but it does feel like it could do with some new torque tube bearings.















This is going to be quite the puzzle.






Clutch seems to be in good shape.



and both discs are hiding in there.






Nothing seems obviously wrong looking into the trans. I shifted into each gear and turned the input shaft, and it all seemed happy.














Thanks. More info is always good to have.

Bigfoot928

solid hub clutch from spec means its probably got good grip but drive-ability may suck. save those pins. you never know when you will booger yours getting them out. find a LSD and really inspect the gears and synchro's. also replace that front seal and the half shaft seals. find the LSD 1st.

captainOCD

I'm glad you noticed that about the clutch because I didn't realize that when looking at. Guess when I take it apart I'll be able to see which "stage" it is. Hopefully it's the less aggressive one.

captainOCD

I disassembled the clutch tonight. I think it looks like a spec stage 2 from the clutch discs, so not sure what to expect for drivability with a more or less stock car. It does look like the clutch was never used.












Clutch aside, the throw out bearing is going to need replacing. It only turns a little bit and seizes, guess rust got to it.

Torque tube also seems like it could do with some new bearings. The engine end bearing that I can see looks almost new, but the trans end looks rusty. I'll have to get them pulled out and see what I'm dealing with, hopefully this weekend.

Cheburator

I wonder if the friction discs from Spec are balanced like the factory ones?

looking good by the way! Nice find/deal

captainOCD

I can safely say I don't know there.

Bigfoot928

don't toss the T/O bearing. some of them are NLA, and you have to replace the bearing in the housing.

captainOCD

I did find a used throw out bearing that I have on the way. I'll save the old one though.

I pulled the driveshaft and bearings out of the torque tube today. Holy crap that was a pain in the ***. I spent almost 2 hours trying to get the driveshaft out prying it out with various blocks of wood (while supporting the hanging out end with a floor jack). It took another hour and a half or so (probably longer) to get the bearings and vibration dampener out.









The impact gun was only able to turn the allthread until about 18" of it was sticking out, then it was absorbing the impacts like a torque stick and I had to do the rest by hand. I didn't want to cut the allthread because I figured I could reuse it later, but thinking back I should have just cut it and spent $11 for a new one. Literally would have saved many busted knuckles, neighbors wondering why I'm in the garage cussing, high blood pressure, etc.



Haven't really looked at them carefully yet. I'm hoping I can clean up the surface rust and press new bearings into them rather than having to spend $400-$500 on new carriers and bearings. Apparently the dampener is for 87hz.




I'm gonna have to clean out the inside of the torque tube, it's got a good bit of dirt in it. I think I'll also take the shifter mechanism off and clean and paint the tube too so it looks nice, even though pretty much none of it will be visible on the car.

captainOCD

Today was a mix of some wins and some fails.

For the wins I got the bearings pressed out of the torque tube. I ordered a new set of bearings and sleeves for them already.

The middle bearing is completely seized as it turns out.


First used a solid block of wood to get it loose so it didn't bend the carrier.


Then two blocks on the sides to give room for the bearing once it was moving.








After getting the bearings pressed out I decided to clean up the torque tube.

Apparently I forgot to take any more pictures, but I ground, wire wheeled, and sanded all the rust spots off, then sanded the whole rest of the tube for new paint to bite.




Then it got primed and painted.


I suppose I should paint the shift rod too.




Now for the fail. I already ordered new bushings for the shift cup and the release arm. I wanted to see if I could get the rear shift coupler off and wound up having to drill out the set screw from it. After that I did manage to get it off. I tried pressing the pin out in the vice, but it was stuck in there pretty good and it kept trying to get cocked sideways a bit (the inside edge pushing into the bushing) when I'd try and press it out. I was trying to be careful, but it slipped and cracked the coupling apart. So I'll be needing to get a new one of those. Might end up getting a used one from 928intl.

Landseer

Nice work on TT.

captainOCD

Shame it's gonna be covered up by comparatively nasty looking heat shields.

captainOCD

I got the replacement shift coupler in from 928intl. It came with delrin bushings in it, but they were pretty warn. Instead of ordering more I thought I'd try making some new ones myself.

I printed these from abs plastic then sanded them to be a snug fit in the coupler and to the pivoting parts. They still have full range of motion and move smoothly. I was finding conflicting info about the glass transition temperature for delrin, but for this abs it's around 105c, so I think it should be ok up on top of the torque tube. If not I'll just have to replace them again.





I did manage to drill out and remove the remaining bit of the grub screw from the selector shaft and then put the coupler back on using the 911 grub screw with the nylon insert.






Also pressed the new bearings and sleeves from garage9 into my torque tube bearing carriers. The carriers seem to be in good shape otherwise. Some soapy water and a toothbrush got all of the scummy rust residue off of the carriers ahead of doing that.






I didn't think about it sooner, but the vibration damper mounts are looking worse for wear. I was going to try reusing them, but after cleaning the crap off with soapy water found that the rubber is starting to come apart on the edges. Rather than risk it coming apart once installed I went ahead and ordered new mounts from 928intl, so they'll be here next week.







I did start on getting my car ready to accept the 5 speed parts. Since this thread has been mostly about the 5 speed swap parts, I think I'll put most of the actual swap updates over in my "problem thread". https://rennlist.com/forums/928-foru...l#post16047659 Anyway, feel free to point and laugh and tell me when I'm doing something stupid.