-----Original Message-----
Date: Fri, 07 Jun 2002 21:54:38 -0500
From: Glen Larson <bigdadglen@earthlink.net>
Subject: Tranny drop - fully on topic


Decided against doing the manual tranny rebuild myself. Figured that I
could get it apart and back together but not sure about determining what
to replace and assembling it right.

I was referred to a guy who is a former Porsche mechanic that does work
on the side. Basically $50/hour and a $500 flat rate to rebuild the
unit, plus parts of course.

The deal is I bring the tranny in so I've got to get it out. Looks like
a bit of work, especially if there are un-cooperative bolts.

I've check www.nichols.nu and looked through the manual. Any last, sage
words of advice before I plunge in? I've got the welded battery box.

Glen
'80 Euro S with absolutely no synchro on 1 or 2 and a weak one on 3



From: Dan [dbrindle@kondratyev.com]
Sent: Saturday, June 08, 2002 2:30 AM
To: 928
Subject: [928] RE: your command request

Glen,

I just got done pulling mine out of an 85.  A week before I pulled an
automatic - trust me the automatic is a lot more work.

Here is how I did the five speed.

1. Disconnect the battery.
2. Drop the exhaust system from the cats back.
3. Disconnect the hand brake cable from the handle inside the car.  Panel
behind the rear seat covers the cable.  Pull the cable from under the car to
remove it from the body.
4. Remove the two bolts holding the brake calipers.  Slide the calipers off
the rotors and suspend with a couple of tie clips.  There is a hole in the
body that makes a great point to attach the tie strips.
5. Remove the spare and locate the plugs going to the transmission.
Disconnect them and push the ends through the hole that has a rubber
grommet.
6. Remove the four bolts connecting the torque tube to the transmission.
7. Remove the rubber plug in the torque tube and remove the cap screw to the
connector on the drive shaft.
8. The hardest part was disconnecting the shifter.  Mine had a rubber boot
that I had to pry back to get to the set screw.  I would be interested in an
easy way to get at this one.  Operate the shifter in the car to disconnect
the shifter from the transmission.
9. Take a scribe and mark the two concentric on the trailing arms.
Alternatively you can clean them and use some spray paint to mark the
current alignment.  Remove the concentric bolts on the trailing arms.  Use a
big screw driver to force the trailing arms down from the body of the car.
There is no need to have them completely clear the car only to be loose.
10. Remove the two bolts by the transmission that connect the cross member
to the trans.
11. Put a transmission jack on the transmission.  Harbor freight sells a
very reasonable trans jack adapter for a floor jack.  They also sell a very
reasonable 2 ton floor jack.
12. Put a second jack under the torque tube to support it.
13. Remove the three nuts holding the top of the shock towers inside the
car.
14. Remove the two bolts on either side of the cross member.
15. Slide the transmission to the rear until it is clear of the torque tube.
16. Drop the trans to the ground.

Alternatively you can disconnect the torque tube from the front and drop the
tube with the trans.  This is probably easier but I have a lift with a
couple of cross members.  Once on the ground then you just need to
disconnect the axles from the trans and remove the mounts from the side and
you have one transmission ready to go.  You might also check out German
Transaxle in Bend, OR.  I think they charge $375 in labor plus parts and the
work comes with a guarantee.  By the time you get done with shipping it will
probably run around $1000.

I think I have put all the steps in.  When I pulled mine it was on the
ground in a couple of hours.  Of course Tom had already removed the exhaust
system.  Now if I can just get him to put it back on.

Hope this helps - good luck and make sure you have the car well supported
before starting on this one.  You should take the opportunity to do a clean
up while you are there, axle boots, shocks and brake pads.

Pictures to follow on the web site when I install this sucker.

Dan the Pod Guy
Portia's Parts