kiwi 911

Your car looks stunning Macca, I need to make the time to have a look at it.......
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Macca

Dean estimated 25 hours minimum to drop engine/gearbox, split gearbox from bell housing, open gear box to inspect and bolt back up. Inevitably there will likely be a few "while you are in there" items such as the fork, 1-2 synchro (this one gets worked very hard too and should be done same time), LSD check etc. If you are lucky and the gear sets are still un damaged then your looking at around 25-30 hrs + $1000 NZD in parts. If you are unlucky add $1500 per gear set. If you want Motorsport gear sets and steel synchors it gets alot worse (steel Motorsport synchro rings around $1500+).

Whilst the engine, clutch and gearbox are dropped Ill do plugs, timing (have solid lifters like 964 now), check and replace if necessary LSD clutch pack, check FLWF & C etc.

Not a bill I was expecting so an expensive outcome anyway you look at it. Good news is Ill finally have a 2nd/3rd gear shift that works (something that hasn't been the case since before I started taking the car to the track (and has got much worse since I have).

New rear wheel drive shafts, air con evaporator and rear wheel bearings and brakes will be fitted after gearbox and engine are sorted.

Jo doesn't get any more holidays this year as the 993 has just hoovered up enough folding to take a month off travelling!

kiwi 911

You have an understanding wife Macca..........

So $10K gear box rebuild - yippee.........

May as well make it $15K and drop in the RS gears......
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Macca

Mate, any time you are passing. Its in the underground "vault".

Dean is off to the States for 3 weeks holiday tomorrow morning so the 993 can wait in my storage till he's back. Its a big work stream this time to make the car bullet proof for the SI Targa so I want him on the ground to manage it.

Thanks for the heads up about Uncles. As much as Id love to go, I have an appointment with Jo tomorrow to see a neurosurgeon about her back. Its probably quite possible to make it but if Im perfectly honest I would say that after all the SITT driving Im not particularly motivated. Howver I will certainly be timing my next arrival to get the 993 out to HD later in the year. Im growing increasingly impatiemnt to get back out there and fear by the time I do I would have done all the other tracks in the country a second time already (NITT + each of teh four we did on SITT are a full stage of the SI Targa!). Would be nice to get there with a box that shifts properly tho....

Macca

Paul. I'm aiming for $5K max on the gearbox including plugs for the engine, timing and a full inspection of all components. There will be another $5K on drive shafts, bearings, improved evaporator/drier and the labour to fit those up along with the new brake/pad set. Add $5K for the brake kit and you get the idea......

I priced a new Porsche Motorsport G50 30 gearbox with 5 x gear set and steel syncho's, shift forks etc up and they run 9K USD without GST or labour! Way too rich for me Im afraid for the Dave or few Macca's benefit it would give on track.

Truth be told I'm actually well over forking over dosh on this car now. I really had hoped the cash bleed would have stopped now. It seems the older the car gets the more I push it and eventually the more it breaks. 1 x 5 day Targa Tour each year with say 7-8 full track days and Im now firmly on board with your medium term maintenance estimates of 10-15K pa and an engine rebuild (top end) every 3-4 years. You and I are either incredibly hard on our gear or just unlucky!

Macca

John. Im still unpacking! Ill buy a drive tomorrow and drop over to you Wed if ok?

John McM

The drives are cheap as chips these days. Put your stuff on it and I'll add the 400gb I have, overnight.

Macca

Paul. Of interest, Dean said that after talking with Nigel and a few others who frequent HD and have needed 3rd gear synchro replacements in the last 18 months they suspect T1 is a large contributing factor. 5th down to 3rd (220kmph down to 100kmph in a GT3) into T1 with an imperfect heel & toe or alternatively not enough brakes means the gearbox is working extra hard here....

John McM

There is a partial solution to this spend and that's to start more of your own wrenching. Take away the time frame need for the car and everything is possible. DIY mechanics have never had better resources than they do today.

Macca

Its a fine plan John but you have to have the tools, space and the time. I have none of those. A gearbox would require specialist tools and some know how. The evaporator matrix is a DIY for a couple of blocks, some beer and a long weekend. Same with the brakes. The drive shafts and bearings require special equipment (pushers, vice etc).

peterC2S

What, and make pink babies??

mjg

There seems to be confusion and poor documentation about that, but as far as I can tell the early mk1s had brass synchros, later ones had steel for 3rd up, and all mk2s had steel for 3rd up.

Macca

Thanks Matt . Makes sense. I looked at Nigel's box before it went together and it had brass so must have been an early one. Steel synchros are good as they last longer but wear the gear teeth out quicker too. A steel 1-2 synchro ring would be nice too. I guess the brass rings were designed to fail in favour of not destroying the more expensive gear set but given the cost to do the job it all works out about the same in the long run.

John, if I recall correctly your 3rd is also a candidate for future attention. Might be good to go look at how they do mine so you can gauge the difficulty of a future DIY. I dont think it's hard but just requires some heavy lifting. My G50-21 box weighs almost 70kg!

John McM

Right now I can shift more slowly and it's fine. However, longer term, yes, it's showing wear. Btw I wouldn't do complex work, but plenty of people drop engines etc in their home garages. First job I'm going to tackle is the strut replacement. Not difficult if you have the right tools.

gt38088

saw Chris arriving at wgtn airport as I was heading out to AKL on business. Now on his regular commute.

Macca solution is use pdk - no heel toe, no speed issues
I reckon with the use you guys are talking the gearbox will need attention every 2 years. Unless you just have the patience to slow the shifts down and don't worry about the times or the guy in front. afterall is fun right?