DDK - Die Deutschen Klassiker

Started the rebuild tonight:

Both shafts fully built and back in the hole with the selectors.



Waiting for the diff to reappear!


And where I finished: Diff in, gear case on, 5th/reverse to go then end case and it’s done.

Having it on the stand makes it SO much easier.

Thanks to Graham and Mike to get me to this stage

I must thank Mike for his brief exit from retirement to set the diff up for me. These skills need to documented somewhere!

Some ‘fun’ ensued as the diff carrier in my box had a different flange thickness to the new one I’d bought so he couldn’t set the backlash.

Luckily the Bainbridge stock came to the rescue with a correct matching diff so it could have my crown wheel fitted and be set correctly.

Turns out my box is a veritable smorgasbord of weird specifications with a later crown wheel and pinion ratio but with mechanical speedo drive pinion shaft that shouldn’t exist as the two changed at the same time!

I knew a couple of the gear sets were later (3rd and 5th) as I’d changed them years back to kill the whining noises.

Will be fascinating (for sad people like me anyway!) to see how the box is with a complete set of fresh bearings and a properly set crown wheel/pinion.

Mike also fitted the oils seals using the correct tools so maybe my goal of a dry box might be achieved this time!

Looking good Gary, seems you are in a good place for your road trip. Did you manage to get a flywheel from MB?

Cheers. Off to the lakes next weekend and we are going in it! …maybe…

I did get a flywheel, but unfortunately by the time I cleaned it up it turned out to have its own issues so I’ve used my original. Probably been like that for years so we continue!

A busy day today!

Finished up the box, popped it on the engine and into the car.

And oh yes, got it running again






The engine crane crane transforms the process, and more importantly my back is still functioning at the end of the day!

Gear linkage/Driveshafts/ARB/arch liners/rear panel tomorrow then time for a drive.

Might even wash it!

Well done Gary, time to enjoy

Silly question Gary, you did oil the box up?

Using the engine hoist is a game changer to say the least.

It’s full now!

I had planned to do it on the stand but forgot so had to pump it in from underneath.

Looking great and ready for summer!

I've forgotten just twice in 38 years with the car, never when Mike has had it because of the BIG label 'ADD OIL'

Filling a 915 with oil for me is right there with CV joint gaskets, esp a 915 with oil cooler (access).

New tyres for me on Thursday, and i can start to bed the brakes in.

After some fun with clutch and gearshift set up it’s all done

No oil leaks yet… but only just properly warmed it up coming to collect my daughter from the station and get some fuel, let’s see when parked up later!






New rotor arm with 6500 limiter is massively over keen! More like 6200 if that, blob of glue will sort that out

Gary71 wrote: ↑Sun Mar 22, 2026 5:30 pm

.

OMFG

2 hot runs in and we have two drops!

Both from the same spot on the gearbox, the upper detent. So cleaned it up again, new washer and as much torque as a short bolt in previously repaired 50 year old corroded magnesium would allow…

Let see how that works after the weekend!

Engine is perfectly dry as it rest of box

Have you tried something in the thread Gary? I have a pot if Fuelseal, which is a thread flange sealant specifically designed for fuel. I used it when I converted the Boxster to a 996 engine as it needed a modified fuel rail. Anyhow, I have also used for threads where oil is the enemy (and no drinking water actually on my high pressure hose real) and it has worked in both applications. It is made by a company called Rocol


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Not a bad shout. There is also ptfe (the gas type) that John M recommended for the oil pressure sensor.
It’s easy to get to so I can try again if it doesn’t get it this time.

Cheers for the tip