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Anyone done a Gearbox rebuild?
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Author:  J.J. [ Wed Aug 19, 2009 9:44 pm ]
Post subject:  Anyone done a Gearbox rebuild?
My box is louder than when I got it. Still ok but I've seen a few non runners on ebay at 150 to 160 K miles with dead diffs. It's clear that sooner or later it's going to have to be replaced or rebuilt. (Have a plan to add some horses which may finish it off!) Sounds mostly pinion but i wonder if once the diff is done then I might hear how bad the rest of it is! I don't want to fit a second hand one as its unlikly to last the car out. This is a daily drive doing approx 10K miles/ year. When ever I've fitted second hand bits they were never as the dismantler described them & I ended up paying twice. Sure they would list mine as good if they got there hands on it!
How big a job is it? All bearings & seals are available & would be around £400 with gaskets.
Porsche shop do a rebuild service. Anyone tried them? Diff only for £600 ish. Should I do the main input output shaft as well.
Been quoted 4K ish for the full box :shock: Syncro seems fine on all gears.
Author:  Brett928S2 [ Wed Aug 19, 2009 10:00 pm ]
Post subject:  Re: Anyone done a Gearbox rebuild?
J.J. wrote:
My box is louder than when I got it. Still ok but I've seen a few non runners on ebay at 150 to 160 K miles with dead diffs. It's clear that sooner or later it's going to have to be replaced or rebuilt. (Have a plan to add some horses which may finish it off!) Sounds mostly pinion but i wonder if once the diff is done then I might hear how bad the rest of it is! I don't want to fit a second hand one as its unlikly to last the car out. This is a daily drive doing approx 10K miles/ year. When ever I've fitted second hand bits they were never as the dismantler described them & I ended up paying twice. Sure they would list mine as good if they got there hands on it!
How big a job is it? All bearings & seals are available & would be around £400 with gaskets.
Porsche shop do a rebuild service. Anyone tried them? Diff only for £600 ish. Should I do the main input output shaft as well.
Been quoted 4K ish for the full box :shock: Syncro seems fine on all gears.


Hi :)

Do not even think about it as an amateur...you wont have the tools or the gauges ...basically its not on....think of it like being asked to rebuild the space shuttle from a pile of parts...BLINDFOLD ....lol :)

Changing a diff is relatively easy though, as long as you do BOTH crown wheel AND pinion together for a matched set...

p.s 4k for a box rebuild is ridiculous.....try a local gearbox specialist...as a guess ...a full rebuid WITH guarantee....around 1k to 2k max...

All the best Brett :)
Author:  J.J. [ Thu Aug 20, 2009 5:31 pm ]
Post subject:  Re: Anyone done a Gearbox rebuild?
Thanks Brett. Sounds like an exchange recon then. Wasn't planing on a complete rebuild. Just to replace some bearings. Will see if I can get a better price away from the Porsche speicalists!
Author:  Ezgeezer [ Sat Aug 22, 2009 8:16 am ]
Post subject:  Re: Anyone done a Gearbox rebuild?
Hello
my 91 turbo gearbox was very noisy so I have rebuilt it.(all the bearings were worn out).The job is quite straightforward if you use the Porsche manuals but there are a few things that are definitely required,
a 30ton press,
a dial gauge with magnetic stand
feeler gauges
a very low value torque wrench
the wife to go out so that the kitchen oven is free !
loads of patience and time, the pinion and diff preloads and relative positions have to be set checked and reset a number of times. This requires a few trips to the dealers for shims which usually need to come from Germany and take a week each time.
All said, if you have the tools and patience then go for it, its good fun, unlike a torque tube rebuild which is a pain !
Cheers
Author:  J.J. [ Sat Aug 22, 2009 6:03 pm ]
Post subject:  Re: Anyone done a Gearbox rebuild?
Thanks. I have a friend with a press. It's how long I can afford to have it off the road thats the problem. If the box is coming off then I may as well do the torque tube bearings & clutch at the same time. Will see what credit crunch quotes I can get first.
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