Twood

As you will see from the photos I have fractured the part of the housing that holds the pivot shaft (clutch control shaft) for the clutch fork.
How do I repair this?
Can this be welded and then re drilled or repaired in any way?
Am I up for for a whole new diff housing and gearbox rebuild?
All suggestions are very welcome.

azander

PChar had the same problem... https://rennlist.com/forums/964-foru...ng-boss-3.html

Steve Weiner-Rennsport Systems

Ouch.

That can be welded and re-machined, however its a job for an experienced and competent machinist.

Ruf964

try the transaxle guys at lake havasau. they do this specific repair.

Twood

Steve

I have been reading the link azander sent:
PChar had the same problem... http://forums.rennlist.com/rennforum...ng-boss-3.html
Jason Andreas feels that the part can be rewelded and machined without pulling apart the gearbox-this will save considerable cost if possible. Your opinion on this approach?

Steve Weiner-Rennsport Systems

Jason is correct; a competent individual can do this properly without disassembly.

Ruf964

steve, do you do that type of repair work?

Ruf964

personally, i would chuck it up in a mill and machine the boss flush or even sunk in the case a bit. then machine a piece of cromoly that will bolt in place of it all together. again i agree with steve, that you need a competant machinst to do this fix either way. the aluminum cases seem weak at this point. i have seen several. just my .02

JasonAndreas

You'll need to find an experienced TIG welder to build up the aluminum in the area. It will help to use a graphite EDM rod as a guide and just weld around it. That will give you a rough opening. You do want to drain the oil and it will help to cool the transmission/use something to dissipate heat when welding it. It will take a few hours/days to do a little bit at a time, pausing to let the thing cool down.

In the eighties Porsche sold a tool (almost idiot proof) for boring out the area when they released a modified clutch release lever shaft bearing. It was special tool kit #9292, Porsche PN 000 721 929 20. Which consisted of an assemble cutter (9292-1), arbor/guide (9292-2), guide piece (9292-4), spring and guide pin (9293-3). All you need is an electric drill (500RPM). The tough part will be finding an old Porsche repair shop in your area that still has the tools.

UncleRemus

Dude, perfect timing

http://www.ebay.com/itm/Porsche-964-...e831d4&vxp=mtr

Twood

Thanks to Jason and Steve and others for their advice. I am going to have the gearbox welded. They have given me the confidence that this will work and I do not have to disassemble the gearbox and the cost saving is massive.

Also my attititude is if it fails (not that I think it will) there is no real cost involved compared to buying a new gearbox housing and disassembling and reassembling the gearbox.

Thanks again Rennlist

JasonAndreas

When it happened to me I sought out the welding instructor from the local vocational high school who, had been TIG welding probably longer than I've been alive.