"TRANSZILLA", side shift 914 - 901 build Options

[mrbubblehead]

after a couple of months of planning and parts collecting i have finally started my transzilla build. it will using a normal 914 side shift trans, with a few up grades, i will be dialing in the ring and pinion back to spec with this build also.

i laid all the parts out on my assembly table to give you guys an idea of all the parts installed.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362881754.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362881754.2.jpg)

[turk22]

scary!

(IMG:style_emoticons/default/hide.gif)

[mrbubblehead]

a friend suggested i do a build thread after i disassembled and cleaned all the parts. so i will begin starting with assembling the pinion shaft. first thing i had to do is figure out the pinion depth. this is done with a combination of shims. this is when you have to put on your thinking cap and do some math.

after using the formulas in the factory manuals i came up needed 1.38mm of shims. rounded up i would actually install 1.40mm worth of shims.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362887160.1.jpg)

this is where have a big assortment of shims comes in handy.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362887160.2.jpg)

then i dropped them onto the shaft
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362887160.3.jpg)

[mrbubblehead]

then i had to assemble all of the spinning gears. this is done by pressing the dog tooth on to the gear.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362888381.1.jpg)

next to go in are the anchor and thrust blocks. the brake bands and the syncro ring.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362888381.2.jpg)

and finally the snap ring. then measure the syncro assembly to see if it falls in the tolerance.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362888382.3.jpg)

after all five gears are assembled, they are ready to be installed.

one thing i forgot to mention. after i disassembled the gearbox i did an initial check. while everything is still dirty and oily i am looking for anything out of the ordinary. metal chips, broken bearing cages, and setting suspect pieces to the side. then everything got a thorough cleaning and recheck. suspect pieces again were set to the side for further investigation. i have a cool little usb microscope that is attached to my garage computer so i can see the magnification on my computer screen.

[mrbubblehead]

the rest of the pinion shaft is just like assembling puzzle. when done it should look like this.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362890577.1.jpg)

and this is the main shaft. no special math for this shaft. just assembling the puzzle. an interesting note about the 901 gearbox is the second gear fixed gear is actually part of the main shaft so you cant really change the ratio for second gear. i take that back. the are a couple of ways to change its ratio. you can use a 904 main shaft. which has a removable second gear. but its big bucks, if you can even find one. or the second gear can be machined off and the new gear can be welded on.
here is the completed main shaft.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362890578.2.jpg)
here is my professionally calibrated torque wrench. (IMG:style_emoticons/default/biggrin.gif) its for the big nut that holds the whole shmeer together.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362890579.3.jpg)
then the washer gets peened over to keep the nut from loosening up.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362890579.4.jpg)

[dfelz]

GO Doug! Glad you started your thread, project look really good (IMG:style_emoticons/default/biggrin.gif)

[yeahmag]

Nice!

[mrbubblehead]

thanks guys. i got the boring stuff out of the way. its gonna start getting good from this point on! (IMG:style_emoticons/default/piratenanner.gif)

[Black22]

(IMG:style_emoticons/default/popcorn[1].gif) (IMG:style_emoticons/default/popcorn[1].gif) (IMG:style_emoticons/default/popcorn[1].gif)

[0396]

Brings back memories - good luck with your build

[mrbubblehead]

next on the list is to put together the intermediate plate.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362961945.1.jpg)

i had to work quickly so i couldnt stop for picture. first thing was to put both bearings in the freezer for 1 hour. then bake the intermediate at 300 degrees for 15 minutes. when the intermediate plate is at a crispy golden brown i pulled it out of the oven grabbed the bearings out of the freezer and gently tapped them in. yes to my pleasant surprise, i had to tap them in. i thought they would just fall in. those bearings are in TIGHT!
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362961945.2.jpg)

while it cooled i prepped the bearing retainer bolts with a little red lock tight.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362961945.3.jpg)

and mounted the chromolly bearing retainer. those bearings are not gonna budge!
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362961946.4.jpg)

[mrbubblehead]

its time to install the main shaft and pinion shaft to the intermediate plate. and install both first gears. and the reverse and idler gear, and torque every thing down. again.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362962960.1.jpg)

i installed it into the jig and finished the torquing.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362962961.2.jpg)

once i was satisfied everything was in its proper order, the now "gear stack" came out of the jig. i installed the detent hardware and shift rods and back into the jig to adjust the shift forks.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362962961.3.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/i722.photobucket.com-12492-1362962961.4.jpg)

[Richard Casto]

a friend suggested i do a build thread after i disassembled and cleaned all the parts. so i will begin starting with assembling the pinion shaft. first thing i had to do is figure out the pinion depth. this is done with a combination of shims. this is when you have to put on your thinking cap and do some math.

after using the formulas in the factory manuals i came up needed 1.38mm of shims. rounded up i would actually install 1.40mm worth of shims.

You are missing the pinion depth money shot! You didn't show how you measured the actual depth to calculate the shim stack. I am curious, what tool did you use to measure the actual depth?

Nice clean work by the way!

Richard

[mrbubblehead]

a friend suggested i do a build thread after i disassembled and cleaned all the parts. so i will begin starting with assembling the pinion shaft. first thing i had to do is figure out the pinion depth. this is done with a combination of shims. this is when you have to put on your thinking cap and do some math.

after using the formulas in the factory manuals i came up needed 1.38mm of shims. rounded up i would actually install 1.40mm worth of shims.

You are missing the pinion depth money shot! You didn't show how you measured the actual depth to calculate the shim stack. I am curious, what tool did you use to measure the actual depth?

Nice clean work by the way!

Richard

thank you richard.... i will take a picture of my pinion depth tool for you today and post it up tonight. my next installment is going to be the pinion depth, bearing preload, and back lash. im now sure how many people would actually do these critical steps, so i wasnt going to spend much time on them. i havent even gotten to the good stuff yet (rubbing hands together)

for anyone whos interested heres a preview of whats to come. my oiling circuit pre install mock up and testing. cooler mounting, pump mounting, plumbing etc. double shearing the shift console.

i just buttoned up the gearbox last night and may install either tonight or tomorrow. fingers crossed.

[Richard Casto]

i will take a picture of my pinion depth tool for you today and post it up tonight. my next installment is going to be the pinion depth, bearing preload, and back lash. im now sure how many people would actually do these critical steps, so i wasnt going to spend much time on them.

I don't think many would (or would have the tools to) do it themselves, but I think they would be curious to see what tools and processes are involved.

Richard

[0396]

I will take a picture of my pinion depth tool for you today and post it up tonight. my next installment is going to be the pinion depth, bearing preload, and back lash. im now sure how many people would actually do these critical steps, so i wasnt going to spend much time on them. i havent even gotten to the good stuff yet (rubbing hands together)

for anyone whos interested heres a preview of whats to come. my oiling circuit pre install mock up and testing. cooler mounting, pump mounting, plumbing etc. double shearing the shift console.


YES count us in on these $$$ shots. I'm very interested in the bearing preload / back lash info. I've read up on several treads stating you have have 'special' tools . Then just last night on I read that IF one changes an open ZF for a ZF LSD ...one does not have to really check all these ...reason being all ZF dims are the same.

Thank you
(IMG:style_emoticons/default/smile.gif)

[Ductech]

He'll I would like to know for that glorious day I track down a LSD in the wild

[mrbubblehead]

I will take a picture of my pinion depth tool for you today and post it up tonight. my next installment is going to be the pinion depth, bearing preload, and back lash. im now sure how many people would actually do these critical steps, so i wasnt going to spend much time on them. i havent even gotten to the good stuff yet (rubbing hands together)

for anyone whos interested heres a preview of whats to come. my oiling circuit pre install mock up and testing. cooler mounting, pump mounting, plumbing etc. double shearing the shift console.


YES count us in on these $$$ shots. I'm very interested in the bearing preload / back lash info. I've read up on several treads stating you have have 'special' tools . Then just last night on I read that IF one changes an open ZF for a ZF LSD ...one does not have to really check all these ...reason being all ZF dims are the same.

Thank you
(IMG:style_emoticons/default/smile.gif)

even a stock ring or pinion change need to be reset. i would be very weary of someone who told you otherwise....

[mrbubblehead]

He'll I would like to know for that glorious day I track down a LSD in the wild

i know right (IMG:style_emoticons/default/beerchug.gif)

im ready for it now.... (IMG:style_emoticons/default/first.gif)

[Richard Casto]

I'm very interested in the bearing preload / back lash info. I've read up on several treads stating you have have 'special' tools . Then just last night on I read that IF one changes an open ZF for a ZF LSD ...one does not have to really check all these ...reason being all ZF dims are the same.

Thank you
(IMG:style_emoticons/default/smile.gif)

I don't think that is a safe assumption. I am sure suppliers to machine diff related parts all the same. And many are likely very close to spec, or similar enough that you could use the same shims in the new as was in the old. But if all of the suppliers (ZF or otherwise) could machine everything exactly to spec, Porsche wouldn't have designed in the use of shims in various places. And all specs have some (+/-) so even if "to spec", tolerance stacking requires shims anyhow. It's not rocket science to check and adjust backlash/preload. It is more of a time consuming and/or tedious job. You can use commonly available tools plus some parts of your own creation if you don't happen to have the "official" Porsche tools. Many (including myself) don't have the special factory tools. It should be done anytime you swap any differential related parts that impact the total differential and case axial dimension (transmission case, diff cover, diff bearings, ring gear, differential housing)

Richard