DDK - Die Deutschen Klassiker

Pulled the output shafts out of the diff then the diff itself before removing the case from the engine.

Input shaft stripped down less one bearing still to go.

General mess!

Box of stuff needing a clean

That brings it up to date, main shaft strip tomorrow and then time to put a parts list together.

All bearings are being replaced including the pinion bearing and Mr Bainbridge has kindly offered to set the diff once I’m ready.

Probably a few if not all syncros will be going on as well.

I’m going to get the cases cleaned and coated and I hope not to take it apart again anytime soon!

Nice work Gary. Have just had the diffs re-shimmed in my race box plus spare and so have 3 gearboxes in various states in the garage and still get hit by the smell of transmission oil every time I go out there. Horrible.

Great work on the porch! Always interested to see when people can turn a practical hand to things outside of cars - I have built a few wooden structures in the last few years including an outdoor living room from scratch, but it is nothing like as pretty in the detail as that. You can’t weld a bit in and have a second go with wood either!


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Fab update Gary. Merry Christmas!

To make sure I put my efforts in googling part numbers in bearing catalogues for hours into perspective I now have a quote from Porsche for the parts…

Full set of bearings, 5 synchros, nuts, clutch fork and release sleeve:

£3230

WTF. And that’s with a 10% discount!

Some of the old bearings are suddenly looking just fine

Some of those prices are disgusting - there won't be anything in there that you can't get from SKF for a tenth of the price. I'm fairly sure I've still got that bearing fit program on a USB stick somewhere as well, although I half remember you already having it?

If you’ve got it listed that would be awesome.

I’m trying to trawl the net for alternatives. The problematic ones are those with the flange on ‘four point bearings’ and the roller bearings that have a circlip groove.


I know the needle rollers are the same as a Honda part for £20 each rather £116+vat each!

Diff bearings are standard ones hence not on this list.

Gary, after countless old car and motorcycle builds,I can recommend "Bearing Boys" Even if i didnt have a part number, I took it to them and got a match.

My quote was £2200 iirc for parts and labour about 8 years ago.
The bearings are silly, special parts.
Bearing Boys are really good.

Thanks for your year update Gary - nice to recap on all that.

Good luck with the rebuild

Whilst trawling the world for answers to the OE bearing price issue I’ve also been doing a basic clean of the cases.

I want to get them vapour blasted and coated but want to check for any issues first.

One I knew of was around the detents so I’ve contacted EMP tooling (after Gitesh had welding done on his case). I’d helicoiled them many years back as they wouldn’t hold any torque.



The surface for sealing can be resolved, but the crack isn’t ideal!

Let’s see what the answer is!

Whilst googling the world of magnesium corrosion it seems that the copper sealing washers under the detent bolts are a really bad idea!

Aluminium next time…

The steel washers elsewhere seem ok, but must avoid copper!

Hi Gary,
That looks nasty but I am sure EMP will be able to help.

Good luck

Gitesh

Whilst I’m still debating next steps on the case, might do a different mechanical fix, I’ve been doing some other bits.

Fitted the old crownwheel to my ‘new’ diff.


In a further probably futile attempt at stopping oil leaks I’ve pulled all the valve covers to flatten the mounting surfaces.
Both the original magnesium uppers were miles off, this first one had a good 2mm of rock end to end!

At the start of the flatting process it only touched on the centre mounting locations:


Some time later… other than some minor pitting in the outer corners a clean surface, and no rock!


As expected the 930 aluminium lower covers were both pretty much ok, but still needed bit of a clean up.


This expensive but annoyingly small box turned up from Germany, syncro rings, nuts, clutch fork, sleeve etc etc.

Next step is to get the standard bearings ordered then summon the courage to pay Porsche for the 5 unique ones!

I’m also going to pull the chain covers for the same flattening process and have a look inside.

Maybe you have already, but use the Type911 lower rocker cover gaskets with the silicon bead on them, none of mine have ever leaked for years and years.