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
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