Porsche 915 Shift Fork Setup and Pinion Gear Backlash Adjustment With Custom Tools

[@ktlspider]

Fantastic job creating the alignment plate and extension rods to mimic a center housing assembly, but at the same time have it be “invisible.” It’s what Porsche should have done originally Also you get an A++ for showing everybody the importance of the rotational alignment of the shift rod “windows” for the dongle engagement. You are spot-on with your assessment that you want the dongle to swing into the windows without any interference. It makes all the difference between having a 915 that shifts ok and one that shifts excellent

[@GarageTimeAutoResto]

Thanks! Next time, I will add a support for the main shift rod so it won't flop around while checking the dongle engagement with the selector forks. This would be the equivalent of installing the nose cone, but way less time. I appreciate you watching and the nice comments.

[@ktlspider]

You’re also on the right track with supporting the shifter shift rod end. The guys with “windowed” center sections often also have a cut away piece of the nose/tail case that captures the shifter shift rod. Doing that mimics how the shifter rod will be positioned during actual transmission operation. So it is definitely good practice to have a setup tool that captures the shifter rod!

[@richardpetit6738]

You never give away! Congratulations!

[@GarageTimeAutoResto]

Perseverance and learning all at the same time

[@nrw34260]

I was going to attempt to rebuild my box myself, but it seems that there are too many special tools needed and too many critical adjustments.

[@GarageTimeAutoResto]

This is very true! It's not easy.

[@GregsGarage]

I've seen the VW shiftfork jig before. It's interesting to see the setup you have made. I think you've got it on the run!

[@GarageTimeAutoResto]

Next time, I'll make an attachment to support the main shift rod too.

[@walterkucharski4790]

Thanks Tom always a great tutorial.

[@GarageTimeAutoResto]

My pleasure!

[@24hourgmtchannel64]

You are a great teacher. After many years I finally aquired a 1982 911 SC in GP white. It's got 62k but the factory single stage paint has tons of nicks to the galvinized bare metal from the previos owner. It looks pretty thin in many spots from years of polishing so that may be an added cause. My plans is to touch up all the chips to make it 5 feet ok and enjoy it for the first year or two before a respray. I'm in Illinois and waiting for the weather to hit the 50's and I am going to change the transmission gear oil. What oil did you use after assembly? Swepco 201 seems to the only recomeded one for the 915 transmission but I would have to order it. I can locally get Valvoline 80W90 GL5 which I'm tempted to try out but it states its not for syncronized transmissions as most 80W90 GL5 which is primarily a hypoid hear oil for differentials.

[@GarageTimeAutoResto]

You don't have to use swepco. I used Kendal 75-90w without any modifiers for hypoid gears

[@24hourgmtchannel64]

@@GarageTimeAutoResto thanks.

[@AndyHolmes-i5r]

When you measure the backlash with your indicator, is the a spec on how far out on the bar you measure? That will affect your reading.

[@GarageTimeAutoResto]

It should be measured at the contact patch. So yeah, there is a radius spec. I just measured the middle of the crown gear diameter and divided by two. Porsche has a factory tool that does this for you.

[@AndyHolmes-i5r]

@@GarageTimeAutoResto Of course.. makes perfect sense. The minute I hit send I realized what you were doing.

[@GarageTimeAutoResto]

No worries, I'm glad to have anyone interacting well th these trans videos 😀

[@gonbad]

Hey can you send out the measurements or CAD file for the plate and rods?

[@GarageTimeAutoResto]

$100 and you can have the parts! Sorry I can't give away my development time.

[@jamesbuckingham8073]

Awesome attention to detail! Half Measures avail you nothing.

[@wayneazmat3444]

Have sold the alignment plate??

[@wayneazmat3444]

I would be interested in buying it

[@GarageTimeAutoResto]

I sold the extra one.

[@elborikua951]

Off-topic - Do you know of a quality business in SoCal to acid dip an entire shell?

[@GarageTimeAutoResto]

Hi Javier. Sorry I do not know of a dipper around here. Too many epa prohibitions.

[@elborikua951]

That was my suspicion. Time to look towards Nevada/Arizona. Thanks for the reply.

[@GarageTimeAutoResto]

Or Mexico!