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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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Practicing my perpendicular parking
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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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bondo
post Oct 6 2004, 09:30 PM
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Practicing my perpendicular parking
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Yeah, I tried the vice grip thing first, until I started shearing teeth off my vice grips (IMG:style_emoticons/default/smile.gif) (whatever the shaft is made of is HARD) None of them were as tight as that first one though, so the vice grip thing probably would have worked fine on the rest. Do you know how to decide how many shims are needed when assembling a transmission from parts? Also, do you know if there is any wrong way to install an H gear as 5th? That is my ultimate goal, and I don't want to screw it up, or change the laws of physics (IMG:style_emoticons/default/smile.gif)
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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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