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911 Carrera RallyCross Project

Posted by BRAIDusa 
BRAIDusa
Paul Eddleston
Elite Moderator
Location: Birmingham, Michigan
Join Date: 09/06/2012
Age: Possibly Wise
Posts: 424

Rally Car:
Subaru Outback Wagon EG33, 911 Carrera



Re: 911 Carrera RallyCross Project
December 28, 2014 04:39PM






















Paul Eddleston
BRAID Wheels USA www.BRAIDUSA.com
Team Illuminata Motorsport www.teamilluminata.com
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BRAIDusa
Paul Eddleston
Elite Moderator
Location: Birmingham, Michigan
Join Date: 09/06/2012
Age: Possibly Wise
Posts: 424

Rally Car:
Subaru Outback Wagon EG33, 911 Carrera



Re: 911 Carrera RallyCross Project
December 30, 2014 05:38PM
I made a closer inspection of the gear sets today. Looks like 1st on the main shaft is worn pretty bad. How do we fix that? The rest of them look OK, to me. Are they?











I also got the diff out. Looks like he only issue in there is a missing magnet pick for the speedo ring. Repairable?














I won't get till work on it again till next year but I'm not sure what to do next anyway.



Paul Eddleston
BRAID Wheels USA www.BRAIDUSA.com
Team Illuminata Motorsport www.teamilluminata.com
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BRAIDusa
Paul Eddleston
Elite Moderator
Location: Birmingham, Michigan
Join Date: 09/06/2012
Age: Possibly Wise
Posts: 424

Rally Car:
Subaru Outback Wagon EG33, 911 Carrera



Re: 911 Carrera RallyCross Project
January 05, 2015 08:44PM
Happy New Year everyone. Feels like I've been away from the car for a month yet it's less than a week. Strange.

Tonight I got to look more closely at first gear on the main shaft. I'm concerned this might be worn. What do you think? Doesn't photograph well though.






Then I got to disassemble the pinion shaft.




I gave everything a quick once over and found a few issues. Here's one obvious problem. I don't think that ring is supposed to be around the dog teeth like that and those bent bits used to be inside it!



I'll post more issues tomorrow if I get chance.



Paul Eddleston
BRAID Wheels USA www.BRAIDUSA.com
Team Illuminata Motorsport www.teamilluminata.com
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BRAIDusa
Paul Eddleston
Elite Moderator
Location: Birmingham, Michigan
Join Date: 09/06/2012
Age: Possibly Wise
Posts: 424

Rally Car:
Subaru Outback Wagon EG33, 911 Carrera



Re: 911 Carrera RallyCross Project
January 06, 2015 08:40PM
Today I did more research, separated the syncros on 1st and 2nd, inspected the rest of the components and drew up a parts list.

The first thing I have decided today is that 1st gear is not worn out. I don't think it is pristine but at $2500 it better fall out of the car and onto the road if it wants replacing. I looked at pictures on line of others and they do look very similar so it stays. Get used to it.

So I managed to disassemble the syncro rings on 1st and 2nd. Those snap rings are pretty tough. You can see the carnage on 1st, 2nd doesn't look too bad.







I'm going to replace everything associated with these two gears, except the gears themselves. I just need a tool to get the dog teeth rings off.


I then looked over the main shaft gears. I've decided to leave these alone as, in my opinion they look pretty good and I've never had any issues shifting 3 to 5,





So here is the parts list so far. Did I miss anything?

1st gear brake band (37)
1st gear dog teeth
1st gear synchro ring (39)
1st/2nd shift hub (41)
1st/2nd shift sleeve (42)
2nd gear brake band (37)
2nd gear dog teeth
2nd gear synchro ring (39)
accelerator pivot bushing (13)
Main shaft lock nut
Pinion shaft lock nut
Transmission Cover O-Ring
Transmission Gasket Set
dog tooth ring tool

There's also a few engine pieces to replace and add a new cutch cable and helper spring. I still have to decide if I'm upgrading the clutch and whether or not to install an LSD. Running out of time not to mention money.



Paul Eddleston
BRAID Wheels USA www.BRAIDUSA.com
Team Illuminata Motorsport www.teamilluminata.com
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aj_johnson
A.J. Johnson
Ultra Moderator
Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,349

Rally Car:
88 Audi 80


Re: 911 Carrera RallyCross Project
January 06, 2015 10:54PM
at those prices, I'd start looking at something like this before I ordered gears... holy robbery

http://www.ebay.com/itm/Porsche-911-G-50-01-Rebuilt-Transmission-Transaxle-5-Speed-Short-Nose-/181623687840?pt=Vintage_Car_Truck_Parts_Accessories&hash=item2a499d8aa0&vxp=mtr
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Eric Ewert
Eric Ewert
Godlike Moderator
Location: Calgary, Ab
Join Date: 05/13/2013
Age: Party Animal
Posts: 355

Rally Car:
volvo 240


Re: 911 Carrera RallyCross Project
January 07, 2015 12:19AM

Indeed.

Thats kinda cool that the engagement teeth are removable. I personally have never seen that mind you haven't been in/seen the guts of too many gearboxes. I assume they thread on?

As far as your concern with the state of 1st gear the t5 manual might help you. They give a chart on what is actually a problem and if you should chuck it or do something about it. For this particular item id say gears are gears so just because its coming from the ford manual doesn't mean its not applicable. However I am no expert at this sorta thing. With any luck I will know if I successfully rebuilt my own gearbox in a few weeks or so.

http://www.camarofirebird.ru/files/t5rebuildmanual.pdf

What I am referring to is at page 5-16 figure 5-5.
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BRAIDusa
Paul Eddleston
Elite Moderator
Location: Birmingham, Michigan
Join Date: 09/06/2012
Age: Possibly Wise
Posts: 424

Rally Car:
Subaru Outback Wagon EG33, 911 Carrera



Re: 911 Carrera RallyCross Project
January 07, 2015 08:10AM
A G50 is a difficult and expensive swap from what I've read and "Rebuilt" could mean less than I'm doing to this one. I'll pass.



Paul Eddleston
BRAID Wheels USA www.BRAIDUSA.com
Team Illuminata Motorsport www.teamilluminata.com
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BRAIDusa
Paul Eddleston
Elite Moderator
Location: Birmingham, Michigan
Join Date: 09/06/2012
Age: Possibly Wise
Posts: 424

Rally Car:
Subaru Outback Wagon EG33, 911 Carrera



Re: 911 Carrera RallyCross Project
January 07, 2015 08:12AM
Quote
Eric Ewert

Indeed.

Thats kinda cool that the engagement teeth are removable. I personally have never seen that mind you haven't been in/seen the guts of too many gearboxes. I assume they thread on?

As far as your concern with the state of 1st gear the t5 manual might help you. They give a chart on what is actually a problem and if you should chuck it or do something about it. For this particular item id say gears are gears so just because its coming from the ford manual doesn't mean its not applicable. However I am no expert at this sorta thing. With any luck I will know if I successfully rebuilt my own gearbox in a few weeks or so.

http://www.camarofirebird.ru/files/t5rebuildmanual.pdf

What I am referring to is at page 5-16 figure 5-5.


This is my second transmission build. The previous was a mini some 30 years ago. One small step......

These press on. How normal is that?

Good luck with your box Eric.



Paul Eddleston
BRAID Wheels USA www.BRAIDUSA.com
Team Illuminata Motorsport www.teamilluminata.com
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BRAIDusa
Paul Eddleston
Elite Moderator
Location: Birmingham, Michigan
Join Date: 09/06/2012
Age: Possibly Wise
Posts: 424

Rally Car:
Subaru Outback Wagon EG33, 911 Carrera



Re: 911 Carrera RallyCross Project
January 08, 2015 07:28PM
Just dropped over $2000 in exchange for some snazzy transmission parts.



For the first time in months I have a free weekend but alas, parts won't be here till Monday sad smiley These cars move a lot quicker when they're not in pieces.



Paul Eddleston
BRAID Wheels USA www.BRAIDUSA.com
Team Illuminata Motorsport www.teamilluminata.com
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aj_johnson
A.J. Johnson
Ultra Moderator
Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,349

Rally Car:
88 Audi 80


Re: 911 Carrera RallyCross Project
January 10, 2015 03:47PM
Yeah not a cut and paste.

In other news we've been trying to track down another 911 or 240z for dad... Never in my life have I heard of so many scheisters in a used car market. The minute these cars started becoming more valuable everyone's idea of "Pristine" or "rust free" seems to have become defined by a Nigerian prince. 4 trips now only to come back with an empty trailer, Last car had multiple Dollar bill sized areas of rot on a "rust free" car. Another one missing a bowling ball sized chunk of clear coat, advertised with "pristine" paint. Lucky for me another urs4 popped up the same night we were in seattle, I took advantage of the empty trailer and now just need to pick it up from his shop.

edit: sorry to derail, just venting a little frustration with a couple wasted weekends

Really fun to follow the 911, maybe throw us a bone every now and again with an update on the quattro winking smiley



Edited 1 time(s). Last edit at 01/10/2015 03:48PM by aj_johnson.
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urs4 (2).jpg
BRAIDusa
Paul Eddleston
Elite Moderator
Location: Birmingham, Michigan
Join Date: 09/06/2012
Age: Possibly Wise
Posts: 424

Rally Car:
Subaru Outback Wagon EG33, 911 Carrera



Re: 911 Carrera RallyCross Project
January 15, 2015 03:42PM
Parts have begun to show up smiling smiley

Kitty thought there was a bird in here.




Maybe one of these magnets will work in my speedo ring.




Still need Dog tooth rings before we can proceed. Due here tomorrow so a busy weekend ahead. I wonder if I can get the transmission all back together before Monday.



Paul Eddleston
BRAID Wheels USA www.BRAIDUSA.com
Team Illuminata Motorsport www.teamilluminata.com
Please Login or Register to post a reply
BRAIDusa
Paul Eddleston
Elite Moderator
Location: Birmingham, Michigan
Join Date: 09/06/2012
Age: Possibly Wise
Posts: 424

Rally Car:
Subaru Outback Wagon EG33, 911 Carrera



Re: 911 Carrera RallyCross Project
January 17, 2015 05:06PM
Removed the dog tooth rings from first and second with the Porsche took. Started to clean parts and reassemble the pinion shaft.








Hope to have the box back together tomorrow.



Paul Eddleston
BRAID Wheels USA www.BRAIDUSA.com
Team Illuminata Motorsport www.teamilluminata.com
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BRAIDusa
Paul Eddleston
Elite Moderator
Location: Birmingham, Michigan
Join Date: 09/06/2012
Age: Possibly Wise
Posts: 424

Rally Car:
Subaru Outback Wagon EG33, 911 Carrera



Re: 911 Carrera RallyCross Project
January 20, 2015 09:02PM
Got the new dogs pressed on at Auto Europe.






Beginning to look like a gearbox again.













Paul Eddleston
BRAID Wheels USA www.BRAIDUSA.com
Team Illuminata Motorsport www.teamilluminata.com
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BRAIDusa
Paul Eddleston
Elite Moderator
Location: Birmingham, Michigan
Join Date: 09/06/2012
Age: Possibly Wise
Posts: 424

Rally Car:
Subaru Outback Wagon EG33, 911 Carrera



Re: 911 Carrera RallyCross Project
January 23, 2015 12:06PM
I think it's safe to say this is now a gear box again.






I even put new bushings in the throttle link rod thingy.




Now I just need the new clutch kit to arrive.



Paul Eddleston
BRAID Wheels USA www.BRAIDUSA.com
Team Illuminata Motorsport www.teamilluminata.com
Please Login or Register to post a reply
BRAIDusa
Paul Eddleston
Elite Moderator
Location: Birmingham, Michigan
Join Date: 09/06/2012
Age: Possibly Wise
Posts: 424

Rally Car:
Subaru Outback Wagon EG33, 911 Carrera



Re: 911 Carrera RallyCross Project
January 27, 2015 06:53AM
I picked up some Castrol transmission oil. Thought we'd give it a try.




and the new clutch arrived from Pelican.






No, we didn't forget to install the ring gear.




Offered it up to the engine which accepted it graciously.




And slapped it all back in the car.




I hope to drive it home tonight smiling smiley



Paul Eddleston
BRAID Wheels USA www.BRAIDUSA.com
Team Illuminata Motorsport www.teamilluminata.com
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