Joel Griffith

My 1982 928 has the classic early 928 2nd and 3rd gear synchro problems and I have two questions regarding this.
1. Has anyone out here rebuilt one of these themselves? The procedure in the manuals looks pretty straightforward although several special tools need to be used.
2. Several times in the past on e-bay I thought I saw technical manuals available specifically for the Type G28 5 speed. Does anyone know of these and if they are available.

Paul D

Joel - I replaced the 1st, 2nd, and 3rd synchros in my 5 sp. myself. I too had the 2nd gear synchro issue and it was pretty straight foward if you follow the manuals. The most exotic tool I needed was a hydraulic press with the associated tools to remove the gearsets. Take/draw lots of pictures of how it disassembles to aid in reassembly. I bought the transmission gasket set to replace all seals and gaskets. I did not do a true rebuild by measuring all tolerances. I just made sure all the pieces went back where the started. No more 2nd gear synchro noises. I needed an extra set of hands when it came time to reconnect the trans-axle but the rest was a DIY job. Hope this helps.

Joel Griffith

Thanks Paul,
It's nice to here about someone accomplishing this themselves. The advice about taking/drawing pictures is very advisable. Years ago I rebuilt a Triumph trans without paying attention to how it came apart. Big Mistake!
Joel
1982 928

Steve Cattaneo

Joel,
This has been my hobby for 6 days a week, for many, many years. I still love it. You’ll definitely need manuals to tackle this job. Like Paul said, documents every step especially the direction of the synchronizer assemblies. On some you can install backwards.

On some models the selector forks for 2nd, 3rd, 4th and 5th gears are not locked on the shift rods with roll pins. They have bolts, which allow you to adjust the position of the forks (just like the VW bug 4 speed trans). Mark the position of the fork to the rod with a file. If you don’t, the synchronizer assembly will not mesh properly and the trans will grind or pop out of gear.

Good Luck
Steve C
The Great White

Joel Griffith

Thanks for the response Steve. I have the full set of 928 manuals on CD ROM. In my first post I was referring to Manuals that deal with the 5 speed trans itself that deal wit the trans in more detail. I could have sworn that I saw these somewhere (E-bay?). Have you heard of these?
Thanks
Joel

Jerry 87 928S4

Joel this is the manual that I had that you may have seen. No more copies though.

Joel Griffith

Aha!
That's the one Jerry. I knew I saw one somewhere. Now that I know one exists I'll have to hunt one down.
Thanks!
Joel