72Audi

To requote the neanderthal who "rebuilt" my transaxle, "Maybe you didn't hear me, I don't make mistakes !"

.... response when asked for the second time what he would do for me if I pulled the transaxle myself and found anything he overlooked or did wrong...

As I said previously I am just going to order all new pins.

Thanks guys,

Bruce Toski

DANdeMAN

Did he look like this


With is tool of the trade

72Audi

funny.
No.
I bet the caveman on the Geico commercials could do a better job ...
BToski

72Audi

Still have not located the tools 9218 and 9219.
Local Porsche dealer (Champion Porsche Audi in Pompano) says he has them but shop foreman just told me minimum shop charge is $110.00 and that is what he would charge me just to break the nut loose and give me the torque reading, "for the record".
argh.
BT

Vilhuer

Buying factory tools is not enough in itself. You also need suitable torque wrench. See WSM pictures what such beast looks like. Custom tools we had made locally do not need this as normal 1/2" or 3/4" torque wrench works fine.

72Audi

Still have not disassembled the main shaft.
Finally got the tools "on the way" but I do not have them yet.

The only tool available in the US from Porsche is 9218 (one on the left in the pic). I just ordered this $218.00) and it should be here in a week. I am in Fort Lauderdale and the tool is at some dealer in Atlanta. I wanted it Monday but they said overnight would be $35.00. I said I don' t need it for Saturday. They said that was only option, overnight or regular .... one week. Guess they never heard of two or three day delivery ? Anyway should be here beginning of the week if they ship today from Atlanta ground unless they are using some Polish shippers. ( I can say that .... I am Polish). I inquired about having one of these made but was told that it would easily be more than the cost of the Porsche tool price. So forget that.

The other tool (on the right, #9219) is a special deep socket, which I believe is 41mm. Seems like a regular deep won't work as, so far, I have not found any 12point metric sockets, 41mm, with internal depth ( to clear the input shaft) of at least 75mm or 3"). Instead I came across a large wrench that is 41mm, 12point and it fits quite well. Bought the wrench for $20 (Sunex brand, argh, probably lousy but will only use a few times) and have already dropped it off at Precision Waterjet and Manufacturing who said they would make a perfectly square hole for my torque wrench for $100.00.

Will xmit pics when I get ahold of both tools and let ya know how it goes.

Bruce Toski

72Audi

I could not find anything but a partial pic of their torque wrench on page 3-211.


It looks like a click type. Is there a complete pic somewhere ?

No biggy. The tool that I am making to replace 9219 will have hole for a standard 1/2" drive torque wrench and it looks like 9218 has a square 1/2" drive hole as well ?

I anticipate my regular torque wrench will give me a reading while undoing the nut that was chiseled on, and to apply the 221 lb/ft of torque during reassembly I will find just stand on the 1 ft lever with a few bricks !

Bruce Toski

Vilhuer

I do not have pics or any specs on that torque wrench other than what is in WSM. To me it looks like 9218 is directly mounted into it, not at all like normal wrench I'm used on seeing. Before these custom pieces were made I tried to find wrench which would work like that but couldn't. I know they exist but not sure if there is some common standard what shape tool mounting points are or if each manufacturer has their own design. There is rectange hole on 9218 so it might be possible to use it with normal wrench too.

I use those tools other way around. 9218 replacement is mounted into vise with extension and 9219 is rotated with 50mm socket and what I call normal torque wrench. 9219's other end has been turned into normal hex head since that pic was taken.

Vilhuer

Found another pic.

Vilhuer

Did interesting discovery other day, to me at least. One local '88 S4 5sp has gearbox casting which has provisions for PSD work cylinder and adjustment bolt. Raw casting has positions for them but final machining hasn't been done. Most likely gearbox was changed some time in the past and casting is whatever spare part was available at the time. I don't believe this to be indication that factory knew already in '88 MY that they were going to make PSD way they did eventually do it.

72Audi

do ya have the casting numbers off of this transaxle so we could double check them ?

BT

72Audi

41mm SUNEX brand wrench $30.00
water jet machine 1/2" hole for torque wrench $106.00

still waiting for the other Porsche tool to hold the "guide sleeve" next to the nut.

BToski

John V

You probably already know this but just in case.... your torque values will have to be compensated since the torsional axis will now be offset by linear distance of the wrenches lever arm.

72Audi

yup, will have to double the reading off the wrench.
If wrench ends up indicating 30lbs/ft that means they only torqued it to 60 lbs/ft
I had the hold jet drilled 12" off from center of the closed / boxed end of the wrench.

Vilhuer

This starts to make sense now. Looking at your pic in first message it seems your casing also has places for PSD parts. Can you confirm? Casting week should be little above casting number.

Numbers in this ex German now Finnish '88 S4 gearbox are:
Casting number 928 301 102 0R = same number as in my '92 GTS gearbox for example
Casting week 06/87 = very early for casting to have PSD possibility build in
Serial G28/12/12/11H00831 = '87 ROW S4 manual with LSD.

Obviously box has been changed sometime to previous MY casting. All numbers appear to be original, especially casting week is convincing.

This has to mean Porsche had pretty good idea they were going to put PSD into 928 more than 2½ years before they actually did it. Wonder what caused delay, control electronics perhaps. Digital dash not being ready is unlikely as '89 MY has it but they do not have PSD. Also its unlikely they would have made castings way they did unless they had diff and work cylinder designs finalized already at beginning of '87.