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Some of you 944 lovers would have endured JasonE’s moaning about the “moan” from the torque tube of his S2. Well – over the last couple of months we: Removed the gearbox and pulled the TT back enough to do a clutch and RMS job, then reassembled everything, as the bearings in the TT didn’t seem all that bad. NB that the S2 TT has a 3mm wide split along part of its lower surface, reputedly to quieten down harmonics from the big 3L engine. The bad news for S2s is that the split can widen with use and can allow the four bearings supporting the quill shaft (the inner driveshaft) to move within the TT. Anyway, the clutch needed replacing along with the pressure plate, throw-out bearing, RMS and spigot bearing, so that was a good job done. Not too bad with two people (even if one was an apprentice – could lift heavy things), a hoist and a transmission jack… With it all back together, clutch was working nicely but of course the noise persisted as we hadn’t really done anything to fix it, apart from spinning the quill shaft and scratching our… beards. Well, Jason was moaning more loudly and nearly as often as the TT, so he obtained a 944T TT from a chap in SA. When it arrived, we looked at the worn splines on the clutch end of the quill shaft and decided the quill shaft was not a good prospect, so we decided to: · Purchase some “Super Bearings” from Black Sea in the US· Drive the bad quill shaft out of the 944T TT, using a 3M threaded rod and rattle gun· Do a clean and paint on the 944 TT · Fit the new super bearings into the 944T TT· Allow the bearings to “sit and set” in the 944T TT for a couple of weeks while we got into the mood to pull the S2 transmission and TT· Got into the mood, and this time knew in advance which spanner to use on which fastener, so work progressed at a good, if steady rate. Didn’t have to mess with the engine bell housing, as we did when doing the clutch· Had to drop the rear suspension torsion bar tube about 30 cm to allow the TT to be removed from the vehicle with clearance for the TT bell housing at the transmission end· Degreased and cleaned the gearbox and fitted a short-shift linkage that Jason had purchased during one of his internet buying frenzies· Drove the good quill shaft out of the S2 TT again using the threaded rod technique· Spline on the S2 quill shaft was in excellent condition (sigh of relief here) so the shaft was cleaned (although it came out of the TT pretty clean)· Lube up the S2 TT and, using one of the old bearing holders as a guide, pushed the quill shaft into the welcoming super bearings in the 944T TT. Only needed a few taps with a soft-faced hammer to do the final length adjustment· Put it all back together, not forgetting to bleed the brakes (after having to disconnect lines to drop the torsion bar tube) and put in new insulating foam around gear lever· Test drive carNot a bad job, if you have 2 people, a hoist and a transmission jack... NOISE IS STILL THERE!
After putting my 951 back into service recently I discovered an error I had made many years ago, aka 14 years ago. The car hadn't run balance belts since 2003 and that was when I made the error. In Apr 2017 I put the balance belts back on and found the engine had excessive vibrations. A check showed the gears were 1 notch off correct alignment but fixing that didn't fix he problem. For a while I thought the issue might be the Torque tube, but I've checked that and its fine. A revisit and closer inspection of the Balance shafts revealed I'd put the upper drive gear on 180 Degrees out of phase. The tell was the fact that the "0" on the gear face appeared in the square window, not in the round window. Doh! All sorted now but what a long time from error to discovery. FWIW the lower balance shaft gear is installed correctly when the zero appears in the square window. Now I'm looking forwards to a much smoother track day next time out, just waiting on parts to rebuild the TT now.