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> 914 transmission disassembly, Step by step, so it can go back together
bondo
post Oct 5 2004, 04:01 PM
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I just took apart my last transmission, and I carefully documented the disassembly with notes and pictures. I did it so I could put one back together, but I might as well post it here for all to benefit from. It is not intened to replace Red-Beard's article, more to supplement it. The parts diagrams and Red-beard's article are not enough to turn a pile of parts into a transmission. (There are three similar tapered washers that are all different thicknesses, for example) You either have to just know where everything goes, or take very good notes while disassembling. I did not fully disassemble the transmission, just the most confusing parts that usually have to come off. I left a bearing race on the input shaft, and a bearing on the pinion shaft. I did not remove the differential. Without further adoo, (I don't even try to spell french) here's step one:

1. Drain the gear lube! Very important! Here's what happens when you don't:


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ambergris
post Oct 5 2004, 06:30 PM
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Holy cow! Cheers and you rock! Great article, and awesome timing, as I am just starting my own tranny disassembly. Instant classic, I say.
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bondo   914 transmission disassembly   Oct 5 2004, 04:01 PM
bondo   2. Remove shifter: (2 13mm nuts with washers)   Oct 5 2004, 04:03 PM
bondo   3. Remove tail cover nuts: (nine 13mm nuts with ...   Oct 5 2004, 04:04 PM
bondo   4. lightly tap tail cover "ears" with a rubber mal...   Oct 5 2004, 04:06 PM
bondo   5. Remove the tail cover once it comes loose. Reve...   Oct 5 2004, 04:09 PM
bondo   The gear that actually does the reversing goes ove...   Oct 5 2004, 04:12 PM
bondo   The roller/thrust bearing goes over the reverse ge...   Oct 5 2004, 04:14 PM
bondo   And the washer with the notch goes on top of the b...   Oct 5 2004, 04:16 PM
bondo   Now tap the 2/3 and 4/5 shift rods into the transm...   Oct 5 2004, 04:23 PM
bondo   With the transmission locked, you can now remove t...   Oct 5 2004, 04:28 PM
bondo   Now remove the 1/reverse shift fork bolt completel...   Oct 5 2004, 04:31 PM
bondo   Then remove the 1/reverse slider hub and first gea...   Oct 5 2004, 04:32 PM
bondo   Next the 1st gear roller bearing and its inner rac...   Oct 5 2004, 04:37 PM
bondo   Now the first tapered washer comes off. It is abou...   Oct 5 2004, 04:39 PM
bondo   Now you can grip the intermediate plate and pull t...   Oct 5 2004, 04:42 PM
bondo   Here you can see the notches in all the shift rods...   Oct 5 2004, 04:44 PM
bondo   Now remove the plug from the bottom of the interme...   Oct 5 2004, 04:45 PM
bondo   Now you can remove the 1/reverse shift rod (make s...   Oct 5 2004, 04:59 PM
bondo   Next, remove the castle nut and washer from the in...   Oct 5 2004, 05:02 PM
bondo   Alternate tapping the two shafts with a brass hamm...   Oct 5 2004, 05:06 PM
bondo   Once you get the shafts out of the intermediate pl...   Oct 5 2004, 05:09 PM
bondo   Ok, for a while we'll concentrate on the pinio...   Oct 5 2004, 05:11 PM
bondo   Next is the second tapered washer. The washer is a...   Oct 5 2004, 05:16 PM
bondo   Now remove the 2/3 slider and its hub.   Oct 5 2004, 05:17 PM
bondo   Next 3rd gear comes off, with it's roller bear...   Oct 5 2004, 05:24 PM
bondo   Then take off the 2.5mm thick flat washer.   Oct 5 2004, 05:25 PM
bondo   Next take off 4th gear. The ridge goes against the...   Oct 5 2004, 05:27 PM
bondo   Now take off the spacer that's between 4th and...   Oct 5 2004, 05:28 PM
bondo   Then remove 5th gear (ridge goes twoards spacer)   Oct 5 2004, 05:29 PM
bondo   Now remove the 4.2mm thick flat wahser.   Oct 5 2004, 05:30 PM
bondo   The last thing to come off the pinion shaft is fou...   Oct 5 2004, 05:33 PM
bondo   Now we move on to the input shaft. Clamp it in a v...   Oct 5 2004, 05:35 PM
bondo   Now pound the locking tab with a screwdriver and a...   Oct 5 2004, 05:37 PM
bondo   Here's where the big-ass crecent wrench comes ...   Oct 5 2004, 05:39 PM
bondo   Once you get that nut and locking washer off, take...   Oct 5 2004, 05:42 PM
bondo   The input shaft parts come off in the following or...   Oct 5 2004, 05:54 PM
bondo   Whelp, there you have it. I hope this helps people...   Oct 5 2004, 05:56 PM
ambergris   :beer1: :headbanger: Holy cow! Cheers and y...   Oct 5 2004, 06:30 PM
bondo   Thanks! Glad to help.   Oct 5 2004, 06:46 PM
Lawrence   Damn. That's a great article. I nominate for...   Oct 5 2004, 08:06 PM
bondo   Looks like it's already in the classics.. I gu...   Oct 6 2004, 12:22 AM
gopack   First of all GREAT JOB and THANKS for the hard wor...   Oct 6 2004, 08:22 AM
bondo   I thought about that but I don't have any arro...   Oct 6 2004, 11:03 AM
joes   Good pics and info, thanks. Where do I find "Red B...   Oct 6 2004, 11:53 AM
bondo  
  Oct 6 2004, 12:04 PM
maf914   Bondo, Great contribution. One day I will need ...   Oct 6 2004, 12:30 PM
bondo   BTW, if anyone needs further explanations or pics,...   Oct 6 2004, 12:36 PM
joes   Does anyone have info on where to get cheap trans ...   Oct 6 2004, 12:45 PM
bondo   You could do what I'm doing.. just replace the...   Oct 6 2004, 01:03 PM
Red-Beard   Wow. Your shop is way cleaner than mine, huh Mike....   Oct 6 2004, 08:20 PM
bondo   Yeah, I tried the vice grip thing first, until I s...   Oct 6 2004, 09:30 PM
Red-Beard   The shims are used to line up the gears with the p...   Oct 7 2004, 05:15 AM


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