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When you get one off the shaft,take it to your local bearing shop for them to do an Interchange ? Unusual double row sealed bearing, so maybe no generic substitute easily available.
Just wait till you see the price of a 2nd gear synchro assy !
Last edited by Schnell Gelb; 07-27-2016 at 01:53 PM.
The bearings are indeed a bit of a issue with these, especially as they are sealed units. They tend to fret out inside the races which makes them howl when they are failing. Great write up here. I would caution a few things. Having rebuilt a number of these with a wide variety of companies, I have seen any number of people try to do this build themselves to find that they are WAY over their heads. A 20 or 30 ton press may not be enough to press the gears off the shaft. I know that we have broken more than one of these in the past, and put a fair amount of stress on our 80 ton press, from time to time. Pulling the gears off with a gear puller has also resulted in broken gears with some DIY members. This really is not the easiest gearbox to work on.
Take care not to put too much heat into the box as well, as this will end badly and cost a lot more in the long run.
If anyone has questions or has a need for bearings let me know. I am always here to help.
Nick -
A Brilliant and generous offering to RL folk. Thank you for the time and effort you put in to documenting all this .
Nobody else has ever done such a complete document. The "Angels" guys did one for the Boxster that came close but Nick's diy account has more photographs to help those of us who are visual learners. The remaining challenge is to find a reasonable price for the bearings. The combined cost of all the bearings you may require is eye-watering.I have searched using the *** & the Porsche part number for interchange bearings but found nothing better.
Last edited by Schnell Gelb; 10-24-2016 at 02:13 PM.
I just noticed on my 01 Turbo that the is a whine sound coming when I press the throttle. Even just a tad very light and it starts. I looked it up also on the Turbo forum and found another good post with the and video of the sound.
Two thumbs up and great job on a long overdue write up.
About to split the case on my 99' C4 only to put new rtv (Loctite 5900) around the case half "nose cone" and the differential cover and possibly the reverse light switch. Under the impression the original sealant has dried out and is now finding it's way through these areas, enough to grab my attention. Did I mention it's a Porsche factory rebuild gearbox lol I know, everyone is telling me to bring it back to the dealer, 2 year/unlimited miles warranty etc... I did the R/R myself, so its faster for me to remove, split and re-seal. I dont have the time or patience to spend waiting 1 month for a diagnosis, only to have another reman-gearbox ordered from Deutschland, nor dealing with my local dealer
My question's:
1. What torque specs did you use to tighten the case half "nose cone"?
2. What position was the gear selector in when taking off and then putting back on the nose cone?
Meaning neutral, first second etc..
3. Any idea as to how to take of the drive-shaft/output flange? Puller or special tool? And same for reinstall..
Just trying to plan this 2nd R/R as efficiently as possible lol As to not sit on this gearbox once it's pulled.
Terrific write OP, thanks for taking the time to document the process. im sure this will help many DIY members going forward. Did you consider re-gearing for quicker acceleration?
If anyone is needing the lower pinion bearing part number 99630280800 I have a few of these for $345 , *** OEM bearing , a lot cheaper than Pelican or Porsche. Ju
st send me a PM.
Could someone please help me on how to remove the nose cone on my C4 ???
Nickhend's instructions say that the cone is ready to remove right after the bolts are off. It's what I did but the best I could get is to separate the cone for about 3/4 of an inch. The shifter looks like still linked to something Inside. I must begin in neutral and begin separating and shift in a gear to lift further until it's stuck at 3/4 of an inch.
07-26-2016, 10:45 PM
