915 Rebuild parts

[Aus911]

Hi All,

I am finally biting the bullet and am going to do a long needed transmission re-build.

My first task is to find a source of parts. 

Where are members sourcing their transmission parts here, in Australia?

Cheers

Ray

[Fishcop]

I've done several 901 and 915 rebuilds...

Before you start ordering, you really need to pull the box down properly and itemise parts to be replaced - it's the only way to get a proper picture of the task and then you can shop about for the best prices. 

I hate to say it, but I rarely use Australian suppliers (though Porsche Australia can surprise you occasionally).  I've use the usual Pelican Parts, Stoddards, and Sierra Madre.  More recently I've been paying more attention to the European and UK suppliers because unlike America, they haven't jacked shipping prices to the point of being ridiculous (a lot of suppliers have chosen to provide 'free' shipping to the lower 48 using OS customers to compensate.

915 boxes are super easy (with the right tools), but don't scrimp - replace ALL synchros (Porsche calls them energiser bands) and dog-teeth.  You're also likely to need to replace some bearings - this is where you'll get F%*#ed all over as they are a proprietary size and expensive AF.  Budget $3500 + clutch, flywheel machining etc...  If you're building the box for yourself long term, consider a few upgrades such as the Wevo internal gateshift (never screw a gear again).

Good luck - they are a great project you'll feel real rewards from doing.

[Aus911]

Hi Fishcop,

Thanks for the reply, Yes I am going to pull the box down for a full inspection prior to ordering. I was just seeing if there was a local supplier (wishful thinking).

Esp thanks for your advice and budget expectation. Strangely your comment "915 boxes are super easy" gives me more confidence, and no, I won't scrimp.

Cheers Ray

[Fishcop]

9 minutes ago, Aus911 said:

 Strangely your comment "915 boxes are super easy" gives me more confidence, and no, I won't scrimp.

I'll caveat the job against other mechanical endeavours   The Porsche boxes are quite simple but you will need to work out a system to crank the mainshaft nut off and then back on again (180 ft/lbs from memory).  I made a tool out of an old clutch plate bolted to a stand and big 41mm (from memory) spanner - but it's a huge amount of torque.  If I was still in Brisbane I'd have given you a hand.

Oh, just be really mindful of the detent pins and the reverse pin - really easy to overlook, but you'll punch yourself in the nuts if you forget

[Coastr]

A DIY 915 box opening is a rare event on these pages, be sure to share

[Fishcop]

54 minutes ago, Coastr said:

A DIY 915 box opening is a rare event on these pages, be sure to share

We used to have regular gearbox parties 'back in the day'

[Mike D'Silva]

3 hours ago, Coastr said:

A DIY 915 box opening is a rare event on these pages, be sure to share

I've done a few now.. they are all going pretty well too. 

 

[81SC]

20 hours ago, Aus911 said:

Where are members sourcing their transmission parts here, in Australia?

 

Albins in Victoria can supply some parts for the 915. As well as the usual offshore suppliers: FCP Euro, Sierra Madre, Pelican Parts, Design 911, etc.

https://www.albins.com.au/assets/Mainstream_Product_List.pdf

 

I have recently discovered these Youtube posts after receiving an email from another USA parts supplier.

 

 

[Mike D'Silva]

21 hours ago, Aus911 said:

Hi All,

I am finally biting the bullet and am going to do a long needed transmission re-build.

My first task is to find a source of parts. 

Where are members sourcing their transmission parts here, in Australia?

Cheers

Ray

If you get stuck, I can try to help. I've done a few now. I don't loan out tools but have most of them required. 

[Aus911]

Hi Coaster, 

I will try and keep this site updated, but I am in no rush so it will take a while.

Hi Mike,

I am still in the phase of looking for suppliers/parts. I really appreciate the offer of support, and look forward to meeting! 😁

Hi 81SC

Thanks for the reply, and for the videos, I also just found these. They motivated me to look further into a rebuild, now with the forums support I feel very confidant.

Hi Fishcop,

I love the motivational pics!!

Cheers all!

[Coastr]

When they are fresh how much whine do you get in top gear?  None?  Some?  Every one I have ever been in whines to some extent.

[Mike D'Silva]

They shouldn't whine anymore in 5th than they do in the other gears. 

However, usually, 5th is the first one to whine... due to the position of the gear in the box, once they start to leak and the level starts to drop, 5th gear is the 1st one that runs 'dry'... fairly common in cars that were maintained on a budget. Requires a 5th gear replacement or if its not too loud, just make sure box is full and put up with it. 

I rebuilt one last year where it was so dry, that the gear and needle roller bearing inside had become so heat affected, that the inside of the gear was not round anymore. It was black, tonnes of carbon, and bits of metal starting to wear off. 

 

[Aus911]

Hi Mike,

Great pics....I just hope that I don't see that inside my box....I think I will feel much better once I get it opened...

[Zelrik911]

FCP Euro is having a Clearance sale:

2nd gear syncro ring for US$85

https://www.fcpeuro.com/Porsche-parts/911/?stype=clearance&page=3&year=1977&m=1&e=770&t=5&b=9&v=10

Porsche Manual Trans Synchro Ring - OE Supplier 91530230104
 

[Aus911]

Hi Zelrik911,

Thanks for the tip, when purchasing time comes I will look at them!! They seem to have some great prices!

Cheers Ray

[Merv]

I can add to the list of reasonably good value parts suppliers in the UK.  Their Porsche range is building and they have DHL fast freight at reasonable cost. Prices are given in AU$ as well.

https://www.heritagepartscentre.com/au/porsche/911.html

[Aus911]

Hi All,

Still researching and through recommendations in this thread I see that Albins can supply the dog rings/gear teeth.

Has anyone used these and do you know if they have the 9deg backcut? (the Rauch & Spiegel brand have the required backcut)

If not does anyone know of anyone who can do the backcut in Brisbane?

Cheers

Ray

[Aus911]

Hi All,

Between work and home I have finally got a start on this rebuild. 

I took my car for a final run, taking note of the transmission, it changed into all gears beautifully, as always hard to select 1st when stopped, just need to let the clutch out and try again. Also the transmission is noisier than it should be. Under high torque operation it almost growls.

Back home and parked her, ready for the work.

Hi again,

Jacked her up and emptied the oils, Hmmmm as expected on the transmission plug I found the usual bits (the last 2 oil changes I also found dog teeth). see pic.

The oil was nice and clean as I change the oil on a regular basis. Got most of the items removed to prepare for the drop, but dinner called. Nothing else of significance found.

Till next update

[Merv]

If you are in Brisbane I would suggest that pop over and chat with Don Munro at DHM in Yeerongpilly.  He could advise and also knows most of the other folk in town who can do quality gearbox repairs.  The debris in yours may be synchro ring pieces but that could have been related to bearing, gear or selector failure/s elsewhere.  There are some specialised tools and gauges needed for sustainable gearbox repair. You can swap out parts, but may face the same problems in 6 months. I have re-built two gearboxes- an MGA and an Alfa, but in each case I gave some cartons of beer to a skilled person to let me watch them do a similar 'box first.

Not sure how many people would let you do that these days! Fishcop's 'gearbox parties' sound a great idea.

[Aus911]

Hi All,

The 1st pic shows the guide sleeve, if you look at the area on the sleeve that is nearest the gear there are wear points from the shifting gear... Is this of concern, so replace or reuse?

The 2nd pic shows 5th gear dog/syncro ring. I am looking at reusing these parts, I was considering flipping the syncro ring, any thoughts?

All advice is appreciated.

[Stepo]

You're a braver man than me, wish I had the time and gumption to tackle myself, watching and learning with interest.

[Mike D'Silva]

2 hours ago, Aus911 said:

Hi All,

The 1st pic shows the guide sleeve, if you look at the area on the sleeve that is nearest the gear there are wear points from the shifting gear... Is this of concern, so replace or reuse?

The 2nd pic shows 5th gear dog/syncro ring. I am looking at reusing these parts, I was considering flipping the syncro ring, any thoughts?

All advice is appreciated.

 

 

 

Was engaging 5th gear an issue? It usually has a much easier time than any of the other gears. That being said, flipping the syncro band is considered a 'budget' fix and not recommended by the pros...  however, if it measures within spec when fitted then it will give you a little more life. If there are too many shiny surfaces, you might have to discard and replace. 

Again, being 5th gear, I think you would get away with it. 

[Fishcop]

I know it's a wallet killer, but you will not sleep if you take any short-cuts.  Replace all your synchros, 1/2 and 2/3 at a minimum - much cheaper and convenient to do it now.  You actually have a fair bit of debris in those photos - I'd be very careful to clean everything really well.  Also take a good look at your mainshaft near first - those splines are known to fail. 

[Aus911]

Hi Mike,

I had no issues with 5th gear, actually all gears were changing without problems.

Hi Fishcop,

I know what you mean re sleeping, and I will more than likely replace all, still assessing at this point. The bearings also look average, so those as well. 

I will inspect the main shaft, thanks for the tip. 

All,

❓   I am considering a new one piece bearing retainer plate your thoughts? Has anyone used the "Albins" brand for this and their dog/gears

Cheers

Ray