944Hybrids: 924/944/968 and 928 V8 Conversions
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HOW TO DO AN ADVANCED SEARCH.

Mon Jul 08, 2013 3:56 pm by Admin


For the benefit of 944Hybrids users there are two search functions available for you to use.
The purpose of this sticky is to explain the "Advanced Search" function because it is much more powerful and is the best choice when researching information.

When you log on to the site a list of options is shown in a line at the top of the page. One option is labelled "Search", use this option (NOT the search box lower down on the right).

After you click on the upper search option, a drop down box appears. At the bottom of this box is a radio button marked "Advanced …

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5th Gear swap...in situ

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5th Gear swap...in situ Empty 5th Gear swap...in situ

Post  simon123 on Mon Dec 16, 2013 6:09 pm

I really did not relish the idea of removing the trans-axle to do the 5th gear swap. I swapped my original 88 NA 5th into a 951 trans-axle and later found that I had swapped like for like. I now have a tall fifth set and wanted an easier job installing while in the car.

I removed part of the spare wheel well to gain access to the rear of the gearbox. The bulk of the cutting was done with a jig saw, finished with sheet metal snips. Look out for the fuel tank strap mounting bracket to the right of the gearbox.

I intend to make a fiberglass piece to close the hole, it will be removable in case I need to get in there again.

Where to cut
5th Gear swap...in situ Cimg2310

The cut
5th Gear swap...in situ Cimg2311

Easy access
5th Gear swap...in situ Cimg2312

Old gears out
5th Gear swap...in situ Cimg2313

simon123

Posts : 125
Join date : 2013-07-26

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5th Gear swap...in situ Empty Road Test

Post  simon123 on Mon Jan 27, 2014 6:10 pm

On the road I'm turning 2000 rpm at 70 mph with the new 5th gear.
Rear wheels are 17" with 255-40 Tires.

simon123

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5th Gear swap...in situ Empty Re: 5th Gear swap...in situ

Post  Rich L. on Tue Jan 28, 2014 11:14 pm

That's an intriguing solution. I struggled to get my turbo s trans into the car only to learn the rear cover is leaking at the seal. I am loath to pull it out again. Thanks for sharing the idea.

Rich
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5th Gear swap...in situ Empty Re: 5th Gear swap...in situ

Post  acorad on Wed Jan 29, 2014 11:58 am

simon123 wrote:On the road I'm turning 2000 rpm at 70 mph with the new 5th gear.
Rear wheels are 17" with 255-40 Tires.
Wow. That's low rpm's (in a good way). I swapped in a significantly taller 5th gear (0.68) than the NA 5th (0.73), and I'm at about 2500 rpm at 70, 265/35 18's on the rear.

https://944hybrids.forumotion.com/t1190p45-5th-gear-options-audi?highlight=audi+5th
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5th Gear swap...in situ Empty Leaking

Post  simon123 on Thu Jan 30, 2014 7:56 am

Rich,
I had the same problem also,  I used a gasket one side and form a gasket on the other side of my stiffening plate. When I changed the gear in-situ I used a gasket each side, no leaks now.

simon123

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5th Gear swap...in situ Empty 5th gear conundrum

Post  Gutterboy on Thu Jan 30, 2014 10:05 am

i applaud the in situ solution but even with my 951 lsd transaxle still sitting in the crate i am pretty hesitant as a newb mechanic to tackle this 5th gear swap after reading the wiki 30 times. Seems like some terribly opportunities to accidentally drop the pin in a bad place even if you have a rag to try to stop it like the wiki says or the springs launch through my drywall with removing it improperly in view of my lack of experience on this.

I am basing these worst case situations on the fact that everytime i have had to rebuild a lawnmower recoil to just put the new rope i on i inevitably @#($ up the spring and have to rewind it back which can prove to be trying sometimes.

What's the thoughts on only tackling this procedure as a savvy mechanic or is easier and less scary than it is made to be in the wiki? I would love to have the lower rpm for the long drives but am extremely hesitant to screw up a perfectly good transaxle that i most likely couldn't rebuild myself if i messed up. Shipping is an arm and a leg to send this anywhere who could do it or fix it after i make a mistake from canada.

Appreciate your feedback on this, and to confirm you can do the full swap of the 5th gear with this hole in your spare wheel well with it still on the torque tube and cv's connected?

Gutterboy

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5th Gear swap...in situ Empty Confirm

Post  simon123 on Thu Jan 30, 2014 5:56 pm

Yes, The above pictures show the transaxle in situ with the rear case and the 5th gear removed.
The Wiki is overkill, if you are careful the springs will not jump out, you have to be very clumsy to do that.
The roll pin in the shifter fork could drop in the gearbox, that's unlikely if you are doing it in the car.
As soon as you remove the 5th gear cluster. secure it with tie wraps to prevent it coming apart. Remove it carefully. Just hope the "new" cluster is complete with the springs etc.

To all of you installing more horsepower you really need to modify the transaxle with a steel stiffening plate that sandwiches under the end cover; Eric (TPC) sells the plates and I believe he can machine the 1/4" of your cover. I had my local engine shop do mine. I believe this prevents the gearbox bursting with the additional torque.

The 944 spec racers want the short 5th gear set, I have sold two on Ebay for $150


5th Gear swap...in situ Cimg2412

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5th Gear swap...in situ Empty Finisher panel

Post  simon123 on Thu Jan 30, 2014 6:18 pm

Here is the fiberglass panel I made to close out the hole.

5th Gear swap...in situ Cimg2413

simon123

Posts : 125
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5th Gear swap...in situ Empty follow-up question

Post  Gutterboy on Thu Jan 30, 2014 9:51 pm

simon123 wrote:

To all of you installing more horsepower you really need to modify the transaxle with a steel stiffening plate that sandwiches under the end cover; Eric (TPC) sells the plates and I believe he can machine the 1/4" of your cover. I had my local engine shop do mine. I believe this prevents the gearbox bursting with the additional torque.

The 944 spec racers want the short 5th gear set, I have sold two on Ebay for $150


curious, from everything i have read the stiffening plate is more for those who are using the NA transmission with the LS1 or for those who would go above and beyond the stock ls1 setup with bigger cams, ls6 intake, etc.

i was under the impression that with the 951 transaxle with lsd, and xschop's big beefy axleshafts and the transaxle mount plate to solidify the unit that i'd be good to go for a street application at 350hp...

i am willing to be educated here and thanks for the thumbs up on "it's not that crazy but do proceed with caution and care". thinking i might move more towards doing this now...

Gutterboy

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5th Gear swap...in situ Empty Belts and braces

Post  simon123 on Fri Jan 31, 2014 7:30 am

I have a 951 LSD Transaxle, Xschops mount and his axle shafts AND a stiffener plate. I once talked to a gentleman who built/sold mid engined kit cars using the 944/951 transaxle and bursting was a common problem, he highly recommended the plate.

This is my thought, if you open the box to change the fifth gear, add the plate, the hard part is removing the end cover.

simon123

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5th Gear swap...in situ Empty Re: 5th Gear swap...in situ

Post  v8carreragts on Tue Feb 04, 2014 1:14 pm

All 016/083 transaxles really should have the stiffening plate. What happens is the pinion is pushed backwards under power and it puts a lot of stress on the rear cast housing where the bearing is. There isn't much to hold it in place. The plate adds significant strength here.

If I was using an 016/083 I would use the stiffening plate without hesitation.
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5th Gear swap...in situ Empty Re: 5th Gear swap...in situ

Post  Rich L. on Tue Feb 04, 2014 1:49 pm

I don't see the stiffening plate on TPC's website anymore. Is it still available?

Rich
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Post  turbobob924 on Thu Feb 06, 2014 10:34 pm

This is another mod planned for this year
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5th Gear swap...in situ Empty Re: 5th Gear swap...in situ

Post  darrenbt on Fri May 30, 2014 12:16 pm

acorad wrote:
simon123 wrote:On the road I'm turning 2000 rpm at 70 mph with the new 5th gear.
Rear wheels are 17" with 255-40 Tires.
Wow. That's low rpm's (in a good way). I swapped in a significantly taller 5th gear (0.68) than the NA 5th (0.73), and I'm at about 2500 rpm at 70, 265/35 18's on the rear.

https://944hybrids.forumotion.com/t1190p45-5th-gear-options-audi?highlight=audi+5th

Have you guys checked the accuracy of your tach/speedo?

I used an app for my iphone's GPS to get my vehicle speed (not sure how accurate that was) then used my tire size and gear ratios to figure out my RPM at a given speed. I've checked the Iphone app against a number of other vehicles and the phone app method seemed pretty accurate.

Simon123 has marginaly shorter rear tire dimensions and a slightly shorter 5th but is indicating a lower RPM which doesn't make sense. I'm curious which one of you gents is right.

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5th Gear swap...in situ Empty Re: 5th Gear swap...in situ

Post  acorad on Sat May 31, 2014 11:54 am

Well, my speedo always reads the same as the CA roadside radar-triggered signs that say "your speed is:___" so I think it's pretty accurate.

My engine scanner read 2430 rpm at 70 mph just a few minutes ago.

Andy
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