OU8AVW's Build Thread, On the road again..... Options

[3d914]

Lookin really nice, Mike. I'm sooo jealous!

[OU8AVW]

Thanks guys. No garage time today, it's 6 outside and I'm working in a tent (IMG:style_emoticons/default/dry.gif)

[OU8AVW]

I worked on the front signals this weekend. Got them painted and partially installed. I bounce around allot as required knowledge and needed parts send me back to the computer (IMG:style_emoticons/default/biggrin.gif)

NOS Euro lenses look sweet! My housing seals seals were in perfect shape too. I replaced the harness seals behind the housing with some good used units. This forced me to replace the connections, they were toast anyway. I'm finding that a fine 3m pad and some tire cleaner cleans up the rubber real nice. Then a quick coat of silicone to give it that dull shine.

[CptTripps]

Looking good man...

[OU8AVW]

Started my transmission rebuild Friday. My amigo Eric gave me a hand. I had the tailshift that came with the car and a sideshift i bought from a member here (who's name i will not mention, you'll see why....)

The hope was to make on good sideshift trans out of these two.

Sideshift on the bench ready for disassembly.



Coming apart. The DAPO put this together without any gaskets. The problem with this is that the pinion lash was off.....

[OU8AVW]

Because the pinion lash was off the pinion went too far into the pinion gear causing wear on the pinion. The pinion and the gear are a matched set. There are numbers that correlate to each other.



So we pressed out the main shaft and pinion from the intermediate plate. The factory tool is pushing evenly on both shafts so they come out together. Much more accurate than a hammer (IMG:style_emoticons/default/biggrin.gif)

[OU8AVW]

Ok, so far i have a bad pinion, first gear was bad and fifth gear was toast too. All this transmission's dog teeth were suspect as were the syncros. Hopefully the second tranny would be in better shape. Remember, this was a working trans i bought here (IMG:style_emoticons/default/blink.gif)

So we pulled the tailshift appart....

Not so good.....



Fortunately Eric had a reasonable pinion and gear. First the bad gear comes off the differential and gets swapped out. We used a big torque wrench to get these to 80lbs...



Then the locking washers are installed. Now I'll have Porsche not VW spec pinion. There is a difference. The Porsche parts are measured and factory tested. Notations are seen on the parts....

[OU8AVW]

Next we strip all the shafts and start the hunt for good parts....
More factory tools make this job much easier.



Next we chalk the shaft up in the lathe to make sure it's straight and we use a little 3m pad on the sealing surfaces to ensure they are smooth. This one checks out.

[OU8AVW]

Now to dig into the gears and sliders. I was in need of a few sliders that we sourced from eric's stash and the other trany. We made sure all the gears stayed matched pairs. Another slick tool holds the recess on the slider.



Then the gear can be pressed out. This tool will also work to install the slider and gear back together.

[OU8AVW]

The gears go back together with new syncros and updated brakes.



I spent some time detailing the case today. More on that next time....
I should be doing the assembly next week with new bearings and seals. I do need a nice 5th gear (ZD). Everything else is fully pimped (IMG:style_emoticons/default/biggrin.gif)

[Bulldog9]

dude, kudos on tackling this. Transmissions scare me... I of course am not doing anything on mine except clean up the outside, and changing the fluid......

[type47]

Nice! I did the trans clinic this last weekend and all those photos and discriptions are what we went through with ours.

[computers4kids]

I learned so much at one of Evil's clinics-very rewarding. You're a brave soul tackling one without Evil. Having those custom tools is will make all the difference.

[OU8AVW]

Evil is the man. He's like the Obi Wan Kenobi of transmissions.
Eric is Yoda (IMG:style_emoticons/default/biggrin.gif)
I am far from doing this alone.

[OU8AVW]

Cool little project. I installed a battery switch using a Porsche center cap as a centering plate.

I machined it to fit....



Finis....

[OU8AVW]

Making steady progress.....

Installed my fresh air system





Sorted the lights, running lights and Pilot lights



Dash face and heater controls in....

[CptTripps]

Keep on it man....it'll all come together real fast!

[OU8AVW]

Installed the rear window and more sound deadening. I'm using peel and seal roofing material. Cheap and effective.

[OU8AVW]

Transmission build continues. We did the pinion depth setting. The pinion and all gears were installed with a single gasket. The setting was checked with a factory tool and dial indicator. It was .20mm to far in. The gaskets are .25mm thick so we added a second gasket. It came up perfect.

This tool approximates a diff and uses the same bearings. A dial indicator is held inside that can be seen inside the hole. It bears on the tip of the pinion shaft.

[OU8AVW]

Next we set the lash. This factory tool attaches to the output shaft. We used a spacer to lock the shaft and pinion so the whole assembly rotates. .15-.20mm is optimal. Mine was .17mm. Done! We also set the drag while we were at it. Drag is a product of how much shim installed, lash is adjusted by where the shims are installed, port or starboard side of the diff.