howdog928

With the help of a couple of fellow 928ers, we have stripped down the parts and removed the water pump for a TB & WP replacement.

All has gone smoothly apart from 2 issues.

1) Attached is a picture of the passenger side timing gear. It looks worn, but wanted to get opinions on it from the forum. How bad is this? Do I have to replace it now or will it keep me going for a little while longer? Funds are tight, so if it will last a bit I will leave it, but if it's too risky, I'll figure out how to buy a replacement.

2) While removing parts, a washer fell into the alternator, behind the propeller. At first we could see it, but then in our efforts to get it out, it fell down again and now we can't even see it. I think we'll have to take the alternator apart to get it out Any ideas / tips on how to go about this? We were trying with a magnetic bit, then I tried an air hose to blow it out. But no avail.
If we have to take the alternator apart, how do I go about that?

Thanks for any input guys,

Howard

Leon Speed

That gear is long gone. You can see it has a ridge toward the end. Done for.

As for the washer, you might get lucky just taking the alternator out and shaking it a bit.

syoo8

+1 on the cam belt sprocket. One can see the curvature from the picture.

Roger Tyson has a limited quantity of lower cost, high-quality cam sprockets. You should give him a call at 928s R Us.

If that is worn, chances are the oil pump gear and the main crankshaft gear are also worn. (As well as the driver's side cyl 5-8 cam sprocket.)

Avar928

As the others have said, your cam gears are shot. The coating is gone and the teeth are already worn down and not flat. They need to be replaced. Contact Roger and see if he has more of his custom gears, $295 each but are high-quality coating and metal and should last the life of the car from here on out.

You're going to be replacing all your gears, camshaft and oil pump gear. The new oil pump gears are steel and you remove the washer that's behind that gear upon installing the new one. Hopefully they aren't too corroded and the gears come off the shafts easily. You'll need to buy a gear puller, I suggest ones that are thin and turn in 90 degrees at the grab. You can buy some at Home Depot. The space behind the cam gear and camshaft gear are VERY tight.

My gears had rusted onto the shafts and it took me 2 days to get the camshaft gear off. Nothing anti-seize and assembly lubrication doesn't fix the next time I have to go back in, if ever.

howdog928

Thanks guys, I figured it was shot, just being hopeful.
I can't afford to go replacing everything in there, the drivers side gear looks fine and still has it's coating on, but I'll give Roger a call Monday to see what he has for that passenger side gear.

On the alternator, we already shook it vigorously upside down, nothing moved. It's well stuck in there, sigh.
How hard is it to take off the front propeller for it to gain access behind?

Chalkboss

I just got cam gears from Roger and he was out of the low cost gears... only Porsche available from what I gather. Good luck to you and that gear is hammered.

whatudrivin

I picked up a set of gently used cam gears from 928intl during last december's sales for $65 shipped. I would call them and see what they have readily available.

linderpat

for the alternator. it is a bit tricky to take it apart. Make sure you mark where each screw comes out from the back. Not hard at all, just be methodical.

howdog928

Thanks Ed, I think that is what I'll have to do to get the washer out.

Attached is a pic of the driver's side gear. I think it is in OK shape and am not planning to replace this one at this time, although I realize it will probably need replacing next time I have to go in there.

Bilal928S4

The metal has started showing through the coating. Have the gear coated or it will look like the other side very quickly.

z driver 88t

Recoating is just around $30 from finish line coatings with DF-1. You'll save yourself hundreds of $$ by just sending it to them. Generally one day turnaround. They are doing my oil pump can crank gear now.

Drewster67

Hows the oil pump and crank drive gear? While you are at - might as well.