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Old 04-08-2009, 07:16 PM
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Photos ATB Install: Pics, Tech, and Pricing

The Monday after our open house we performed our first ATB install on a Cayman. The install went very well and was done with the gearbox in the car by Our very own Porsche Master Mechanic Jim Reilly.

We now have a standardized price of $1000.00 including sales tax for this installation for Planet Porsche members.

This pricing includes a 4 wheel alignment because the left rear cross brace and rear subframe diamond brace have to be removed and it is very difficult to keep the rear alignment values in once these have been removed.

This is the installed price for cars that do NOT require any shimming. If shimming is required it will be billed out on a per hour basis as required plus the cost of any shims used.

Now on to the fun stuff. A special thanks to bwass24 for allowing us to photograph the installation so we could share it with you.

The first 2 pictures show the left side of the gearbox after the two braces have been removed but before the left axle has been removed.

The 3rd picture shows the inside of the gearbox after the differential and side cover have been removed. You can see the pinion gear on the right side of the picture.

the 4th and 5th pictures show the stock differential on the bench with the side plate and stub axle still installed.
Attached Thumbnails
ATB Install: Pics, Tech, and Pricing-img_2045.jpg   ATB Install: Pics, Tech, and Pricing-img_2046.jpg   ATB Install: Pics, Tech, and Pricing-img_2047.jpg   ATB Install: Pics, Tech, and Pricing-img_2048.jpg   ATB Install: Pics, Tech, and Pricing-img_2049.jpg  
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Old 04-08-2009, 07:22 PM
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Photos Re: ATB Install: Pics, Tech, and Pricing

Here we have:

Another angle on the side plate and stub axle

3 close ups of the inside of the gearbox case

2 pics of the ring gear after it has been separated from the stock differential
Attached Thumbnails
ATB Install: Pics, Tech, and Pricing-img_2050.jpg   ATB Install: Pics, Tech, and Pricing-img_2051.jpg   ATB Install: Pics, Tech, and Pricing-img_2052.jpg   ATB Install: Pics, Tech, and Pricing-img_2053.jpg   ATB Install: Pics, Tech, and Pricing-img_2054.jpg   ATB Install: Pics, Tech, and Pricing-img_2055.jpg  

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Old 04-08-2009, 07:26 PM
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Photos Re: ATB Install: Pics, Tech, and Pricing

More pics:
The stock open differnetial without the ring gear with the bearign still attached.

Close up of the stock differential gears

The Quafife ATB prior to bearing and ring gear installation

2 close ups fo the Quaife

Ring gear test fit, notice that it is not seated. The ring gear has to be heated in an oil bath to 100 Degrees C prior to fitting.
Attached Thumbnails
ATB Install: Pics, Tech, and Pricing-img_2056.jpg   ATB Install: Pics, Tech, and Pricing-img_2057.jpg   ATB Install: Pics, Tech, and Pricing-img_2058.jpg   ATB Install: Pics, Tech, and Pricing-img_2059.jpg   ATB Install: Pics, Tech, and Pricing-img_2060.jpg   ATB Install: Pics, Tech, and Pricing-img_2061.jpg  

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Old 04-08-2009, 07:28 PM
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Photos Re: ATB Install: Pics, Tech, and Pricing

3 more pics

Another angle of the ring gear test fit

2 pics of the ring gear in the oil bath prior to final fitting

I have a few more pics trapped in the camera at work, but I'm at home right now so I can't post them.

The oil bath is good old Dexron ATF. And yes that is a deep fryer we're using. And yes Jim took it home to make dinner. Clean ATF is used for every installation to help eliminate any foreign matter getting on the ring gear.
Attached Thumbnails
ATB Install: Pics, Tech, and Pricing-img_2062.jpg   ATB Install: Pics, Tech, and Pricing-img_2063.jpg   ATB Install: Pics, Tech, and Pricing-img_2064.jpg  
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Last edited by Drew@FCM; 04-08-2009 at 07:30 PM.
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Old 04-08-2009, 07:39 PM
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Post Re: ATB Install: Pics, Tech, and Pricing

The rest of the installation goes as follows (note this is a simplified explanation).

Both bearings are reused and installed on the ATB.

The ring gear is installed to the ATB. It is a very tight fit. After heating the ring gear just barely fits over the ATB and needs to be drawn in very carefully with NEW ring gear bolts. Note: The old bolts can not be reused

The ATB is then reinstalled in in the gearbox case and the preload and backlash are checked. If all is well re-assembly continues.

After everything is reassembled we install fresh Shell Transaxle 75w-90 gear oil. This is a Porsche and Ferrari specification oil, it is difficult to get but we prefer it to the Mobil 1 gear oil for two reasons. #1 We have not found the correct Euro spec Mobile 1 gear oil to be available here and #2 the cars have improved shift quality with the Shell gear oil.

If you have questions please post them here. If you have friends that need ATB installation please let them know we are available.
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Old 04-08-2009, 09:49 PM
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Re: ATB Install: Pics, Tech, and Pricing

Drew good stuff! Thanks for sharing. What did you think of driving the car after the install and were any shims required in this instance?
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Old 04-09-2009, 08:49 AM
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Post Re: ATB Install: Pics, Tech, and Pricing

No shims were required for this installation. However that will not always be the case.

Driving the car after the installation in normal driving there was absolutely no noticable difference to the car, which is at is should be.

When the car is pushed hard in something like a tight 2nd gear bend the stock differential would give up and have a PSM intervention from wheel spin of the inside rear tire. With the Quaife the car just keeps accelerating and if you wanted to hang the tail out under power you could do so easily, especially in a low grip situation (I did not since this was not my car, nor did I have permission for such antics). On higher speed corners the Quaife imparts a nice planted feel that is subtle but absent from the car with the standard differential.

I think the big benefit will be for cars driven in fowl weather and especially cars driven on track. I have done a few laps in a Cayman S on track with sticky tires and during tight 2nd and 3rd gear corners the inside rear tire just spins and forward thrust is lost, this is especially problematic when PSM is left on since it kills all forward thrust.

We have plans with another customer for a Quaife installation on a Cayman that will see track use with sticky tires. If the owner agrees to let me drive it on track I will be able to compare it to the last Cayman S I drove on track with the stock differential.
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Old 04-09-2009, 09:44 AM
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Re: ATB Install: Pics, Tech, and Pricing

I think you will like driving a TBD equipped Cayman at the track, I know I do.
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Old 04-09-2009, 01:38 PM
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Re: ATB Install: Pics, Tech, and Pricing

Originally Posted by Drew@FCM View Post
Both bearings are reused and installed on the ATB.
Thanks for the photos and your informative posts. As an alternative, I didn't like the idea of reusing the pressed on bearings, especially when it's far easier and much less expensive to replace them during the ATB install than later. I chose to spend a few bucks extra for peace of mind.
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Old 04-09-2009, 03:57 PM
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Re: ATB Install: Pics, Tech, and Pricing

I just wanted to offer a big thanks to Drew and the folks at FCM. The installation was done in exactly the time frame you predicted and my car is even more of a pleasure to drive.

Your comment
On higher speed corners the Quaife imparts a nice planted feel that is subtle but absent from the car with the standard differential.
is right on the button. It's hard to describe but there's clearly a difference when coming out of an aggressive turn.

One question though...how do french fries cooked in ATF taste? Are they red?
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Old 04-16-2009, 08:45 AM
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Re: ATB Install: Pics, Tech, and Pricing

What are the preload and backlash specs that you used to verify that the install didn't need shimming?

Regards,

MJ
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