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Old 08-11-2016, 03:00 PM   #1
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Josh,
Glad you found it useful to receive all that info. Please let us all read your promise in return to publish you DIY with photos and I can offer more.
As you mentioned, we need to share all the secrets, not jealously guard them. There will still be plenty of work for the few companies who repair these gearboxes. Most Forum members want to learn the secrets to learn/understand what the repair involves before they pay well over $1000 for a job. An insignificant number of people actually have all the tools.equipment,time and guts to try to repair one of these gearboxes.
Erik Johnson is one of the few who understand this and generously share info. Some of his less transparent competitors then disparage his technical credentials. Very short sighted imho.
A "transmission guy"may be a problem because this car is different ! Ask Erik about such experienced transmission guys who when extracting or pressing on the bearings buckle or damage the shaft ! It is hollow ,as you will see. Hence the need for the insert tool. And the heat- freeze tricks.
The problem is that a 20 tonne press or puller may exert more force than the hollow shaft can withstand. And you can only remove replace 2-3 times(per Getrag) before the shaft must be replaced.
Another debatable issue - the new bearings - remove their grease seals ?? The new seals will fail eventually,as yours have. The failed seals are unfortunately still good enough to exclude gearbox oil so ironically the bearing fails from lack of lubrication despite being in an oily environment(sound familiar to the IMSB ?)
The other overlooked issue is the frequency of oil changes for the gearbox and the correct oil.There are many cars that have the original fill in there and have 100,000++ miles !And /or they get GL4 as the refill !!
But those issues for another Thread :-)
Ask here how many people would like to buy copies of the NickHend insert tool ? Nick did a great service by taking the time to share his experience:
http://rennlist.com/forums/996-forum/945482-996-transmission-rebuild-and-pinion-bearing-replacement-diy.html

Last edited by Gelbster; 08-11-2016 at 03:10 PM.
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Old 08-11-2016, 08:31 PM   #2
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Yeah I'm guessing my fluid hasn't been changed. Like I first mentioned if it weren't for the random oil leak due to the media blasting, I wouldn't have known how horribly bad my fluid was. And it wouldn't have lead me this far. Right now she'll be serviced just by new fluids. But I'll estimate by Winter time I will tear it down. So I can take my time.

About to respond to Erik's PM now.
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Old 08-11-2016, 08:55 PM   #3
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Oh and I mean a "Transmission guy"... As in a high skilled and trained Master ASE Tech who works for me. Not some guy I know... lol. I understand hearing someone say "I know a guy" or something of the sort kinda can seem far fetched.

But My resume goes as far as being a owner/operator ASE tech for a small automotive performance shop out in Albuquerque, NM. The people I know, lots of them build cars for hobby, repair and maintain cars for a living. Some work under me. I even know Engineers with a vast list of exotic tools like CNC Machines, Plasma Cutting Tables and 3D Scanners but spend their spare time designing and building custom one off parts for Exotic cars. These aren't your everyday "my dad is a mechanic" people.

BUT not trying to brag, just trying to get more info on my own car. I for one don't have any certifications in german vehicles. My knowledge is basic but I am not a noob hehe.

I honestly was expecting something a lil more.... outrageous. a Pole and a puller..... Not exactly the special tools I was expecting but the more I know the easier the vehicle seems to work on. Just seems the details of working on a porsche from the looks of an outsider remain a guarded secret. Everyone thinks they are super exotic on repair costs and ability to work on. But these people obviously don't know what its like to own a high hp DSM, or a built rock crawler that you stupidly wanna daily drive haha. Porsche is not hard or expensive. Maybe a lil more than some.... 70 dollar oil changes. Order only parts. Prices are pretty decent on things like spark plugs and alternators and oil filters. There is nothing special there. Vehicle has an IMS Bearing..... So do some others.
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Old 08-12-2016, 07:32 AM   #4
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"Josh,
Glad you found it useful to receive all that info.
Please let us all read your promise to publish your DIY with photos.Then I can offer more."
Special tools :
The Kukko 20 ton slender arm puller - the 2 Arm design (compared to 3 arm) seems a needless risk. AS Erik has hinted, the gears can be damaged/cracked if excessive force is used to pull them off the shaft. Perhaps a Bearing Puller/Splitter attachment is a better tool? I presume it would need modification to fit. You have the resources to do that !
https://www.amazon.com/Sunex-52BS-Bearing-Splitter/dp/B000SOSHAI/ref=sr_1_6?s=automotive&ie=UTF8&qid=1471015858&sr=1-6
Erik may have some helpful suggestions about this?
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Old 08-12-2016, 08:26 AM   #5
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Quote:
Originally Posted by Gelbster View Post
"Josh,
Glad you found it useful to receive all that info.
Please let us all read your promise to publish your DIY with photos.Then I can offer more."
Special tools :
The Kukko 20 ton slender arm puller - the 2 Arm design (compared to 3 arm) seems a needless risk. AS Erik has hinted, the gears can be damaged/cracked if excessive force is used to pull them off the shaft. Perhaps a Bearing Puller/Splitter attachment is a better tool? I presume it would need modification to fit. You have the resources to do that !
https://www.amazon.com/Sunex-52BS-Bearing-Splitter/dp/B000SOSHAI/ref=sr_1_6?s=automotive&ie=UTF8&qid=1471015858&sr=1-6
Erik may have some helpful suggestions about this?
I'll definitely do what I can. I'll video it if need be. Go live on Facebook haha jk. I'm definitely a photo wh*re... I shoot everything but myself lol but I'll gladly shoot all pics and info I can find.

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Old 08-12-2016, 08:35 AM   #6
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Josh.
Thank you. I am sure your contribution will become a Star entry in the DIY section.
If you need help with dimensions or photos,let me know. I have 2 of these gearboxes awaiting repair in my garage. [QUOTE=DarkStar;506376]I'll definitely do what I can. I'll video it if need be. Go live on Facebook haha jk. I'm definitely a photo wh*re... I shoot everything but myself lol but I'll gladly shoot all pics and info I can find.
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