chaoscreature

I am taking apart my transmission to diagnose not being able to get into 2nd, 4th and 6th gears.
The good news is that so far I have not found mcuh metal shavings or debris.
The bad news is that means I haven't found out why things aren't working as they should yet.

I got stuck here trying to get these two large nuts off. I have already chiseled the detents back as best as I can but they are on there tight!
Is it okay to use an impact gun to try and break them loose?
I will need to borrow the special tool 9253 to get them both off, but for now I can't get either.
Are they both standard right hand threads?

Mike J

The tranny is not a place that I have had to venture yet (thank god) -> do you have the factory manuals you are working from?

If you have time, please take pictures, it would be useful to have these for reference.

Cheers,

Mike

jstyer

^^^^ Yes, please take some pictures as you go, as I know I would find it very beneficial as well!

Pete Debusmann

I used an impact gun in conjunction with the special tool to keep the shafts from turning. You can make a version of the tool yourself using the center section of an old clutch disk and some flat metal stock. Use the flat stock to connect the center of the disk to one of the 4 holes that are used to bolt the tranny and motor together.

Pete

chaoscreature

I will swing by a local shop and see if they have any "dead" clutches laying around. I am still on the fence about replacing mine or just putting it all back together still.
They have the actual tool too, but if I make one i won't need to borrow it again when I re-install. They also have the special puller which will save me some time.
I made a tool to hold the output flanges steady while I removed the center bolts. It was just a piece of aluminum with two holes in it.
I will get some pictures up later tonight.

Thanks for the input! Impact gun it is!

trophy

The cause of 2nd, 4th and 6th issues are teh bearing races that are beneath each gear. They have a plastic race that breaks.

Keep taking tons of photo's. Once I get my engine back together I will be tackling the transmission.

chaoscreature

Trophy,
I have read about the bearings and also about chips in the ring gear causing this proble.
There were some small filings in the differential case that I pulled out and placed on a napkin. Nothing huge, but bigger than the normal very fine metal powder.
I am new with photobucket, but I am posting the pictures there.
Here is the link:
http://i1292.photobucket.com/albums/...ps73b8ba51.jpg
Sorry I didn't take more during the actual dismantling but really everything up until now has been pretty simple.
The back housing comes off by just removing all the M8 nuts (13mm wrench) and giving the housing a light tap with a plastic hammer. The only thing that catches on the way out is the little detent ball for the shift linkage adjuster.
The side housing for the differential is also pretty straight forward. Remove the two M12 bolts from the halfshaft housings (17mm socket). I made the little aluminum too, to hold them. Mine came off pretty easy. Once the bolts out give the half shaft a little tug or a gentle pry and they will slide right out.
Remove more 8mm nuts and then give the aluminum cover plate a few taps to get it moving. Once the cover is off the whole differential just pops right out. It's really very easy.
This week I will get into the more interesting parts of the rebuild!

chaoscreature

Nope, I guess the link just takes you to one picture...
Here are more:
http://i1292.photobucket.com/albums/...ps2cddecc2.jpg
http://i1292.photobucket.com/albums/...ps0f12616a.jpg
http://i1292.photobucket.com/albums/...ps54b480ed.jpg
http://i1292.photobucket.com/albums/...psc685cf8b.jpg
http://i1292.photobucket.com/albums/...psd5b48a6e.jpg
http://i1292.photobucket.com/albums/...psdbbcade4.jpg
http://i1292.photobucket.com/albums/...psa25e3d29.jpg
http://i1292.photobucket.com/albums/...ps8bcd0490.jpg
http://i1292.photobucket.com/albums/...psf37f6359.jpg
http://i1292.photobucket.com/albums/...ps96788abb.jpg
http://i1292.photobucket.com/albums/...ps08fd0fe5.jpg
http://i1292.photobucket.com/albums/...ps8af82f9f.jpg

Bill Verburg

This is from a friends heavily tracked 993 w/ stock bearings
the culprit


collateral damage


if you are tracking the car get rid of all the plastic bearings and brass syncros and tinny shift forks

trophy

As per Bill, I would also look at adding an oil cooler.

race911

Even on the street cars, once you look at the components, you've got to wonder what they were thinking. On the other hand, not like we're tearing into these things right and left.

Bill Verburg

Everyone that seriously tracks their car that didn't replace the bearings the first time around will need to do it the second time, the second time around was when those shots were taken.

e9stibi

And do not forget the shift forks as mentioned before. I had the 3/4 gear fork failing and was lucky that it did not cause any further damage to the RS internals in my custom box. It still was an expensive act because I did the upgrades to steel synchros, too.

Bill Verburg

It's mainly just the 3-4 fork that needs to be updated
you want 950.303.113.04

here it is, along w/ a steel and brass syncro

chaoscreature

I still can't get over how expensive the steel synchros are... I want to replace them but I may not be able to.
I am pretty positive one of those needle bearing is the culprit, but I won't know for sure until I open the center section. I did three tranny flushes and never had anything fall out.

I may not get to work on the transmission much this week, I am working long hours + my new commute gives me very little couch time with the wife.

Thank you all for the feedback!