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WEVO 356-5 SPEED User manual

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356 - 5 SPEED
BUILDING MANUAL
Subject to modifications Edition 2018 Rev3 Printed in USA
Technical stage as April 2018
All Content ©WEVO 2018
INSTRUCTIONS
INTRODUCTION
How do you build your 356 5-Speed kit
the way we intended….?
• Your 356 5-Speed will be built by combining your kit of new parts with donor parts from your Porsche
901, 911 or 914* donor transmission.
• The kit you have purchased includes all the parts necessary to assemble the 356 5-Speed with the
exception of those original Porsche parts that will be harvested from the donor transmission.
Your donor transmission will yield the input and pinion shafts, crownwheel gear, all 5 gear ratios, the
shift rails and shift forks, the reverse gear assembly and all the bearings. Many small hardware parts
are also re-used.
• The major components re-used from your existing 356 transmission installation are suspension parts,
the axles and the axle tube assemblies. Transmission mounts, throttle bell-crank, clutch cable bracket
are all transferred too, along with your clutch release bearing. The 356 transmission removed from
your car can be carefully stored in a fully assembled condition once the axles have been removed.
• Your 901, 914, 911 series donor transmission may require regular service repairs, or replacement
bearings, synchronizers etc. But for the purposes of explanation, we will assume your donor transmis
-sion has been inspected and the donor parts for the 356 5-Speed repaired to fully serviceable con
dition in any application.
• Due to Copyright and in deference to the superb factory instructions widely available for the 901,
914, 911 series transmissions, we do no reproduce any of these original Porsche instructions or
diagrams.
* If your donor transmission is a 914 Side Shift transmission from 1972 – 1976, you will require extra parts.
OVERVIEW
Subject to modifications Edition 2018 Rev3 Printed in USA
Technical stage as April 2018
Which 901 Transmission as my donor….?
• Once your parts kit has been ordered, the next step in your WEVO 356 5-speed conversion is to
source your donor Porsche 901 family transmission.
Parts harvested from the donor will be used along with your 5-Speed kit parts to build the finished
356 5-Speed transmission.
• Four different Porsche 5-speed transmissions can be used as a donor. They all have subtle variations,
so understanding the donor models is a key part of preparations.
• More than 215,000 vehicles equipped with the Porsche 901 family transmissions were manufac
tured, so there are plenty of core transmissions available. Even if (as Porsche themselves claim…)
75% of all 901-equipped donor Porsches are still driving, discounting those cars still leaves us with
more than 50,000 potential donors for the 356 5-Speed kits!
Subject to modifications Edition 2018 Rev3 Printed in USA
Technical stage as April 2018
Which 901 Transmission as my donor….?
Porsche 901 Transmission – the original.
The first version of 901, commonly known as the “Chilled Cast” version, is an all-aluminum casting used in
the rear engine cars (911 & 912) from 1965 to 1968. It was available in both 4- and 5-speed versions.
You will require a 5-speed version to have all the parts needed.
Porsche 911 Transmission – the magnesium version.
The second version of 901, commonly known as the “911 transmission”, is an all-magnesium casting that
was used in the rear engine cars (911 & 912) from late in 1968 through the end of 1971. The 911 trans-
mission was available in 4- or 5-speed versions. You will require a 5-speed version to have all the parts
needed.
Subject to modifications Edition 2018 Rev3 Printed in USA
Technical stage as April 2018
Which 901 Transmission as my donor….?
Porsche 914 Tailshift Transmission – the early one.
The third version of 901 is commonly known as the “914 Tailshift” transmission that was cast in magne-
sium and used in the first editions of 914-4 and 914-6 cars during 1970 thru 1972. The 914 Tailshift
transmission was only available in a 5-speed version.
Subject to modifications Edition 2018 Rev3 Printed in USA
Technical stage as April 2018
Which 901 Transmission as my donor….?
Porsche 914 Sideshift Transmission – the late version and
last of the series.
The fourth version of the 901 is commonly known as the “914 Sideshift” transmission, also cast in magne-
sium and was used from 1973 to the end of 914 deliveries in 1976. The 914 Sideshift transmission was
only available in a 5-speed version.
Subject to modifications Edition 2018 Rev3 Printed in USA
Technical stage as April 2018
Which 901 Transmission as my donor….?
Subject to modifications Edition 2018 Rev3 Printed in USA
Technical stage as April 2018
• Of these four versions, the 901, 911 and 914 Tailshift are the most desirable donor transmissions.
These three versions will yield every part required to complete your 356 5-Speed kit.
• The 914 Sideshift transmission will supply all the gears, shafts, sliders, hubs, shift forks, spacers etc,
but only one of the three shift rails required and therefore require a few parts from another source.
Although the 914 Sideshift transmission is not a 100% donor, they are also the newest of the donor
cores and should not be overlooked as a great source of majority of the parts at economical prices.
• The beauty of the 901 family of transmissions is complete modulatory of the design and the important
fact that parts can be interchanged from all models, even between and the 4 and 5 speed ver-
sions to some degree. There is a wide variety of original ratios available from the different model four
and six-cylinder engine applications and there is a range of new ratios also available from the after
market gear manufacturers.
• Rebuild components for 901 series transmissions like sliders, drive teeth, synchro rings and bearings
are all still readily available and, with the exception of a pitted CWP gear set or internal corrosion
from poor storage conditions, nearly every donor core can be restored to good functional condition
to build a 356 5-Speed.
• There are some subtle technical variations in the assembly dimensions of the different versions and if
of consequences, these are covered in the technical notes and guidelines for assembly.
• Once you have your donor core you will need to establish the condition of the core and make pro
vision for any repairs that would affect the operation or reliability of your new 356 5-Speed transmis-
sion project.
• There are no special requirements for standard 901 series parts used for the 356 5-Speed transmission.
The evaluation of condition would be the same if you were servicing that 901 transmission to be in-
stalled in the original vehicle.
• The safest route is to work with an experienced Porsche transmission builder. They can complete an
inspection of the components and make the recommendations of any replacement parts required.
• If you are experienced and confident with the servicing of 901 transmissions, the donor parts for the
kit should be reviewed for serviceability in the normal manner expressed in the Porsche factory manuals
for the 901 series of transmissions.
Further donor Transmission Considerations
Subject to modifications Edition 2018 Rev3 Printed in USA
Technical stage as April 2018
• The input shaft (also often called the mainshaft) from your donor 901 / 911 / 914 transmission will
require modification. This is a relatively simple task for a technician with the correct equipment - a
lathe. Included with the kit is drawing X3-040. Use this drawing to complete the shortening of the
input shaft. The shaft must be disassembled from all its gears, bearings etc.
INPUT SHAFT
356 5-Speed Product Specifics.
Subject to modifications Edition 2018 Rev3 Printed in USA
Technical stage as April 2018
• Two critical set-up procedures of your 356 5-Speed are the Pinion Depth and CWP (Crown Wheel
& Pinion) backlash. These are familiar technical terms to a technician who is experienced with the
Porsche 901 series transmission.
• These critical procedures are performed in the normal manner developed by Porsche and explained
in the Porsche workshop manuals for 901, 914 and 911 transmissions. The variations in set-up
dimensions and calculations follow the year of manufacture, so take care to identify the source of the
parts and decode the markings on the parts correctly.
• The traditional 901 CWP set-up tools seen in the Porsche manuals can be used to accomplish these
tasks when building a 356 5-Speed. The pinion depth is adjusted using the normal shim stack on the
pinion shaft, with fine adjustments available with the intermediate plate gasket in conventional
Porsche manner. The 356 5-Speed kit includes unique intermediate plate gaskets in 0.10mm and
0.15mm thickness.
• As an efficient alternative, a simple gauge block tool for pinion depth setting has been developed
by Windrush. The X3-073 tool fits in position of the right hand side cover and access via the LH side
cover opening is used to feeler gauge the pinion depth. For customers in the USA the X3-073 can
be rented from WEVO. There are separate specific instructions for using the X3-073.
CROWNWHEEL & PINION SET-UP - PART 1
356 5-Speed Product Specifics.
Subject to modifications Edition 2018 Rev3 Printed in USA
Technical stage as April 2018
• The Crownwheel backlash is achieved by adjusting shim thicknesses under the differential carrier
bearings. This adjustment procedure was introduced by Porsche with the 901 transmission.
Due to the unique carrier bearing dimensions, the shims required are also peculiar to the 356
5-Speed. The X3-042_XX series shims are available in all the incremental sizes necessary. Your kit
includes the full selection of shims, of which only a few will be used, the balance will be redundant,
but it is never known exactly which shims are required before tackling this procedure – the resultant
set-up is matched to your CWP gear set. The nominal design dimension is for 3.0mm shims for both
carrier bearings.
• Differential carrier bearing pre-load should be in the region of 0.2 to 0.3mm.
CROWNWHEEL & PINION SET-UP - PART 2
356 5-Speed Product Specifics.