Transmission rebuilder?

[John Cody Forbes]

Brett Dikeman wrote:
> On Jul 31, 2006, at 9:27 PM, SuffolkD at aol.com wrote:
>
>> Who would the list suggest sending a spare 200 20V tranny to for
>> checking out
>> and possibly rebuilding?
>
> I have the name of a guy who does Porsche transmissions-<snip>

> Brett

I do Porsche transmissions. I've done a 944 box once (done countless 
901/915/930/G50, even a dozen 962's) and I have reason to believe the 944 
box is pretty durn simmilar to the Audi boxes of simmilar era. I;d be 
willing to work somethin out for an on the side style job, but I'll warn 
that shipping the thing arround the country would get costly.

Disclaimer: The following is based on a knowledge of P-car trannys and 
*SHOULD* apply to yours, but I can't promise that I'm absolutely dead on.

Honestly my advice is to just pull the case apart (do not mess with the gear 
cluster) and take a look arround yourself. Pulling the magnetic drain plug 
(remember to remove the fill plug first ALWAYS in case its stuck) would be a 
good hint. Drain into a clean pan of dark color so you can look for 
shimmering brass bits. Anything other then a light dusting of metal on the 
magnetic drain plug is cause for splitting her open for a detailed look. A 
metal-flake effect of brass in the drained fluid is only a minor issue, 
really it's somewhat normal, but any slivers/shards/bits of brass signifies 
that it would be a good idea to look at the syncros. Bits of brass that look 
like baby shark teeth means it's time for a syncro or two. Now I've never 
pulled a quattro trans with a center diff, but bearing that in mind 
splitting the case is easy and special-tool-less work.

Really you CAN pull the gear cluster apart without much in the ways of 
special tools. You will need some type of puller to get the gears off, a 
good torque wrench for the nuts on the ends of the input and output shafts, 
and the only tricky one is an assembly jig. The most important thing here is 
remembering what you took apart in what order. Marking the shift fork 
positions on thier shafts is a must do. Patience is a virtue. A digital 
camera is even better.

Heres some pics of a P-car (964) transmission with the tail cover off to 
give an idea of what you are up against if you open it up: 
http://jcforbes.com/jcfpics/964transmission

Notice 5th and reverse are right inside the back cover, but the rest are on 
the other side of whats known as the "Intermediate plate". The jig I spoke 
of earlier is basically nothing but a plastic intermediate plate which you 
use to hold everything still during assembly. On this 964 trans the 
intermediate plate is more of an intermediate cover, you can see the 13mm 
nuts that hold it to the bell housing up near the diff cover. Remove those 
nuts all the way arround the case and the gear cluster and that cover/plate 
slide off as an assembly (caution, its heavy). This is as far as you would 
go apart for an inspection. Again without knowing about center diff removal 
removing the cluster is as easy as a few dozen 13mm nuts and a 
rubber/plastic mallet for helping get 2 covers off. I'll take a look at the 
200 bentleys at work along with the family album tomorrow to see about what 
it takes to pull the center diff off.


-Cody "Even longer post" Forbes
http://www.5000tq.com
'86 5k noT noQ
'86 5k noT noQ - Parting Out
'87 5ktq
'87 5ktq - Fast. Really Fast.