Steve's unending Progress thread, Air compressor setup recommendations Options

[stephenaki]

Well, haven't had much time to work on the motor as of late but I did get the timesert kit in and fixed the small bolt issue. I was hoping to get more done than that but it's been a bit hectic as of late. Can't do much this weekend since the wife is in Copenhagen, Denmark with her friends and I have the denizen of destruction for all this past week and weekend. Working on teaching her how to pour a good scotch! (IMG:style_emoticons/default/biggrin.gif)

Wife gets back tomorrow but I then take off for NC for a conference next week and get back on Friday at which point I get the youngun again since the wife will be in Paris for the weekend with some other friends of her. I did get the oil in the Toyota changed this morning, took me a whopping 15 minutes to include filter change. Of course the knucklehead in front of me took a friggin hour! (IMG:style_emoticons/default/blowup.gif) Some people should not be allowed to work on their cars...wait, I'm probably one of them (IMG:style_emoticons/default/av-943.gif)

So, I guess this project is at a standstill at the moment; say la vie. (IMG:style_emoticons/default/bye1.gif)

[stephenaki]

Well, I finally got started again...just in time to head to Africa...again. I did get the oil sump bolt holes for the taco plate done so that should be a non-issue.

After some vigorous cleaning and other work, I have the motor out of the basement and partially assembled. Cleaned up the pistons and cylinders, reinstalled them along with the seals and cylinder head. Need to put in the oil tubes and rods then can finish the rest of the motor assembly. I am pretty sure I have covered all the bases on oil leak possibilities! (IMG:style_emoticons/default/blink.gif)

Moved the gearbox to the basement yesterday, will clean that up and replace some seals when I get back from my foray into the wilds of Africa. Once that is done, I need to clean up the heat exchange system and do some brazing to fill in some holes in the exchanger. Haven't done brazing in years but I think I can figure it out without too much problems. It wasn't that hard as I recall.... (IMG:style_emoticons/default/happy11.gif)

Once that is done, on to the final assembly! I need to have it done before June as I have to re-register it on post. Once I get it past inspection the next project is to replace all 4 brake calipers with Eric's rebuilt ones. After that, I ain't touching her until I get it back stateside. Need to work on my MG motor so I can tackle that project when I return to the states.

Oh wait, I forgot, need to fix the engine bay mounting brackets after I get the car up and running. Otherwise she won't close. Will have to pull off both brackets and put in new ones. One is riveted in so won't be an issue, the other unfortunately is welded! That should be fun (IMG:style_emoticons/default/lol-2.gif)

[Cairo94507]

Any progress is good progress. Good luck.

[stephenaki]

OK, started on the transmission yesterday. Fun...I got the rear plate off but then hit a snag. I have followed Red Beard's instructions as well as Bondo's in the classic's thread but the two shift rods refuse to allow me to 'tap' them in.

I can get either the 2/3 or the 4/5 rods down but when I get one down the other won't budge. So, frustrated, I did more on the motor. Got the tubes, rods, valve train and oil cooler installed. Even remembered to put the cylinder head tin on first this time!! Not that I have ever installed the tubes first... (IMG:style_emoticons/default/rolleyes.gif)

So, I have a bit more on the motor and she is done, I just need to get the transmission torn down, inspect the gears and conduct repairs as needed. Anyone got any ideas on what I am possibly doing wrong on the transmission tear down? I sent Bondo a PM and left a note on the PP forum as well. Unfortunately, I am traveling again tomorrow so won't be able to pursue this more until I get back.

As a last question, anyone ever blast the trans case to clean it before painting? I don't have a cleaner available but I do have a blaster but want to get feed back before I tackle the case; if I can blast it the cleaning will be quicker otherwise, I do the old fashioned hand and wire brush method. (IMG:style_emoticons/default/unsure.gif)

[Dr Evil]

I think you need to review my pictorial on removing the stack. You can not select 4/5 and 2/3 if it is working correctly. You only need to select 5th (rod in) to pull the stack. The rest of them dont need to be messed with.

Click on my rebuild link below and I have instructions for pulling the stack.

Need a rebuild DVD???

[stephenaki]

I think you need to review my pictorial on removing the stack. You can not select 4/5 and 2/3 if it is working correctly. You only need to select 5th (rod in) to pull the stack. The rest of them dont need to be messed with.

Click on my rebuild link below and I have instructions for pulling the stack.

Need a rebuild DVD???

I though you were out, I will PM you. Will look at your thread, hopefully I can tackle it when I get back to Germany this weekend. Thanks.

[stephenaki]

OK, so, after three weeks of traveling to take care of my father who passed away this past May. I finally got back around to the car. Mike, AKA Dr. Evil, sent me his DVD for tranny rebuild which I began watching to see how the written tutorial coincided with the video. I like the video better as I learn better seeing the actual action so thanks Mike!

Now, the only thing I will complain about is the fact that the good doctor makes removing the snap rings off the dog teeth easy... (IMG:style_emoticons/default/dry.gif) not so much. Although, I think he had a bigger tool than I did (IMG:style_emoticons/default/laugh.gif) Seriously, his snap ring removal tool was bigger than the dinky German one I have and I believe that size does make a difference in this case.

So where do we stand right now? Well, the case is being cleaned, will get it back next week and, the gear stack is completely broken down.


Well, I didn't understand the 'roof line' comment at first while watching the video but once I 'looked' at the gears and sliders I understood what he meant. As anticipated in Mike's comments, the slider for 4 and 5 wasn't in too bad shape but the 2/3 slider has some flat roof tops and need's replacement. I will probably replace both slider for good measure. What concerned me more was the 1/R slider which is the expensive one. I am think that this is toast, thoughts?


I will attach a picture of the synchro rings in the next post for comments.

[stephenaki]

OK, pictures of the synchro rings; I stacked them together and took the photo. I am thinking a couple will need replacement but I need to re-watch the inspection portion of the video before I complete the assessment.


Will probably order everything this week but have a heavy travel schedule for July so won't get to it until August. (IMG:style_emoticons/default/confused24.gif) In the meantime, hope all you fathers out there had a happy father's day! (IMG:style_emoticons/default/biggrin.gif)

[Dr Evil]

4 bad rings (IMG:style_emoticons/default/sad.gif)

Your first slider needs a shot across the flat side at the teeth, basically a profile shot from the outside in. It looks gone in the original pic.

I have parts for low $$ (IMG:style_emoticons/default/wink.gif)

[Dr Evil]

Oh ya, I will bet that you have a bad 2-5 slider, particularly on the 2nd gear side, and bad teeth on 1st and 2nd (maybe 3 and 4 as well looking at those rings). PM me and I will get you a parts list.

[stephenaki]

4 bad rings (IMG:style_emoticons/default/sad.gif)

Your first slider needs a shot across the flat side at the teeth, basically a profile shot from the outside in. It looks gone in the original pic.

I have parts for low $$ (IMG:style_emoticons/default/wink.gif)

Yeah, I re-viewed the part about the rings and figured I'd need 4 new ones. I'll get you some better shots tomorrow after work of the #1/R slider. Of the other two sliders, one is what I would consider toast and the other looks usable. Will get some better pictures to you tomorrow to evaluate via PM.

I'm gonna price out the parts at the local Porsche dealer down the road from me for shits and giggles but have a feeling it will be a bit exorbitant! (IMG:style_emoticons/default/rolleyes.gif)

[Dr Evil]

my email for pics is MakeMy914go at yahoo

[stephenaki]

my email for pics is MakeMy914go at yahoo

Pictures sent.

[stephenaki]

OK, so, after close to two months on the road between Africa and the US I am finally back in Deutschland for almost a whole month! (IMG:style_emoticons/default/biggrin.gif)

So I began re-assembly of the transmission starting with the pinion gear.

As one can see, this went fairly smoothly. Of course it helped that I had Mike's DVD playing as I did it. I would stop, rewind, pause, then move forward again to make sure I had things straight.


Yes, that's a potty training seat in the background, anyone need one?

Next, on to the drive shaft assembly. Again, same thing, play, pause, reverse, play, pause, move forward. I thought I was doing well until I tightened down the stretch bolt.

What I noticed in Mike's video was the whole pinion assembly turned freely when he turned the drive shaft. Mine did too UNTIL I tightened the bolt the the required 80ft lbs. After that, it didn't turn like it did before. (IMG:style_emoticons/default/sad.gif)

So, I sent a note to Mike and what you see above is where I have stopped for today. I don't want to get too far along if I need to disassemble the gear stack again to make sure I put it together properly. Hopefully I can tackle it a bit more later tonight or tomorrow. Slowly moving forward and yes, I painted everything yellow, better to see leaks with!

[Dr Evil]

Did you put the washer under the stretch bolts?? Sounds like they are missing and if so it will bind.

[Dr Evil]

Sorry, scratch my last. I thought you were talking about the out put flanges.

If binding happens after tightening the main pinion bolt, then I am betting the impression that you may have mixed up the thrust washers under 1st, 2nd and over fifth.

[Dr Evil]

A couple of other thoughts:

Are the gears with steps on them oriented correctly?
3 with step towards int plate
I can see 4 is correct
Is 5 correct?

Still thinking thrust washer issue. There are 3. The thinnest goes under 1st. Under 2 and over 5 needed to be kept not-mixed-up as doing sow will give you your symptoms.

[stephenaki]

Mike,
I will check on everything you posted as a potential culprit and let you know what I discover.

[stephenaki]

So, upon inspection, Master Evil correctly deduced that I had boogered up the Pinion shaft assembly. (IMG:style_emoticons/default/dry.gif) Mixed up the spacer after 5th gear on the shaft. Fixed that, put it together, torqued it and TADA! (IMG:style_emoticons/default/smilie_pokal.gif) Works like a champ.

So on to the rest of the assembly, got the forks on and adjusted according to Mikes intensely detailed procedure for tail shifters... (IMG:style_emoticons/default/blink.gif) he, he, he, he...will post pictures later. Began the inspection of the case and installed the seals and, as Mike pointed out is often the case, no throw out bearing guide clips were anywhere to be found. At least he had one in his video, I had none! So I'll be stopping by the local Porsche dealer to see if I can get my hands on a pair.

Shouldn't derail the rest of the assembly though so will move forward the rest of this week with the hopes of getting it put together by the end of the week! Famous last words (IMG:style_emoticons/default/dry.gif)

[stephenaki]

It's done! (IMG:style_emoticons/default/piratenanner.gif) The Tranny that is, still have more work to do on the car but I got the final piece on this morning and then made sure all the bolts were torqued properly.

I almost had it done on Saturday but the tail cone gave me a bit of a challenge and I was tired so I figured I'd try again the next morning.

Mike's video was a tremendous help and he has the patience of a saint when dealing with retards like myself! (IMG:style_emoticons/default/lol-2.gif) Now, I need to get to work on the shift linkage, heating system and then re-do the engine bay brackets and she should be rolling. Once I get the motor married up and everything mounted we'll see if I put everything together correctly on the tranny.

Some pictures, again, yes, its 'sunflower yellow.' Easier for me to see leaks with!








We head to Tuscany for a mini-vacation then I am on the road again for work so the next step will have to wait a bit. Hopefully I can get it done before it gets to cold.