DDK - Die Deutschen Klassiker

I am ready to start rebuilding my 519 dual mount gearbox with new bearings, synchros etc but I'm a bit confused on a couple of bits

PET shows the bearing (18 on the pinion shaft (17) first followed by the adjusting shims (20) - however, on mine the shims came first before the bearing





However, they are well and truly mullered.

Is this because they were installed incorrectly previously? (I suspect it has been rebuilt at some point in its life)

Should I rebuild with the layout as per PET?

Should I use the same number/size of shims that it has in now after the bearing if the layout is indeed incorrect?

Also, the new bearing from Porsche has 13 rollers, the old one has 12



is this because an inferior bearing has been used previously and Porsche have improved things or does it not really make any difference?

Finally, given that this is a 519 type, where the shift detent springs and balls are in the left side casing not the intermediate plate, I have put the springs (correct ones for reverse and forward gears) in first followed by the balls, but where do the 2 gear lock detents go? (item 69)

Right, phone call to Mike Smith at PRServices http://www.prs356.com/ has cast a bit more light on my questions-

1. It would appear that after the change over at gearbox number 11001 the shims were installed as per PET - after the bearing - prior to this, like mine (number 10575) the split case boxes, the shims were between the end of the pinion and the bearing.

2. The number of shims will depend upon what backlash measurement I find with the feeler gauges between the pinion and crown wheel, so I'll order the same number and add/remove as required

3. The more balls in your bearings the better

4. The detents go between the two rods to stop the potential for more than one gear to be selected

A huge thanks to Mike for giving up his time (again) to help out

This is great information - keep it coming!

It would awesome to see photos of your rebuild (or even better video!). It might give some of the rest of us the confidence to tackle these sort of tasks in the future.

Out of interest where did you get the PET software? I've found the pdf catalogues but no sign of any actual applications...

Cheers!

Ages ago on another thread

Dakota wrote:Hi
if you don't already have an Elfrink book on 356 repairs etc get one it has a very no nonsense approach to everything including a fine section on gearbox rebuilds , also please do replace your syncro rings as they kind of work the hardest in the gearbox especially second to third , ring and pinion mesh is critical but you seemed to do a fine job on you 911 engine so should not be beyond you!
yours Bill.

Just realised I missed this post when I asked some similar questions a few months ago - sorry Bill but you're absolutely right - this book is an absolute must for 356 work, just got myself a copy after re-reading my old thread and your excellent advice to get one - its fantastic!!

roboguy wrote:Out of interest where did you get the PET software?

I believe you can buy it from Porsche - I personally happened to find a spare copy burnt to CD somewhere in the Lakes

I'll take some photos of the rebuild and post up, just need the new shims to arrive first

Great book ...I agree !!

Another Idea is to ask Charlie White ...Should be a link on the 356 registry for a copy of the workshop manual for the 519 (He used to sell copies) ...I have the one for the later C 741 box and its great

has his photo copying got any better? I ended up getting orginal books in the end as the pictures where not too hot shall we say

I got mine 4 yrs ago ...photocopier was ok then ..but I have seen some where he mustve had a toner problem