Most informative posts. I could have easily lost a case of beer to Tom Farham who "claimed" he could change the solid boot without disassembly of the bearing housing from the tube. I am certain, now, that he had this method in mind.

Admittedly, it seems to work as the pictures will attest. It does not seem to be a method for the faint of heart or first timers as has been suggested. Although illustrated in the VW manual thanks to the posting by Jon, no reference is found in the Porsche manual to support this technique. Perhaps the Porsche Engineers did not consider this a "proper" repair procedure abeit it may save considerable time to get the assembly out of the unit repair workroom. Enter the split boot--even faster and, of course, uglier. AND, most important, cheaper overall.

I dare say that it appears to be a messy operation from the pictures even requiring surgical gloves, lubricants and tools of choice. Clean-up without saying as you would not want the assembly slipping away from you on installation. No mention is made of slipping the retainer over the big end of the boot. Perhaps this operation pales in comparison to stretching the little end of the boot over the bell. And, I imagine that turning the boot back from inside out is no piece of cake as well.
I cannot see what I am typing anymore. This must be a built in routine to limit the post response

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Albert Tiedemann, C356C
"The Hermit", Reg #4998

last post continued:

Most folks want to powder coat parts for durability these days. I suppose it could be done without disasembly but that would have to be answered by someone in the business or has done it before.

Jon is silent on the use of this method, but I would always disassemble the pieces to put on the boot. No chance of tearing--regardless of how cheap you resource the boot. And, you do not need the Matra 400 press as has been suggested. The one from Harbor Freight works well and if something breaks, just buy new --they are cheap enough.

If you disassemble the parts, you will need some mandrels and support fixtures. Getting the pin retainer hole and slot in tube to line up is usually the biggest stumbling block. But Porsche guys are clever and they can always come up with something to ease the task although the factory offers no guidance in this respect. You will find that some tubes are machined differently, so mark their position for reassembly. The factory tool illustrated in the posting by Jon that supports the bell end of the tube for pressing on the bearing housing could have a little more length on the section that goes inside the tube to ease the alignment of vertical for the pressing operation.

Running out of seeing space agian, so in closing I ask how long does it take to do the task from prep to finish without disassembling.

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Albert Tiedemann, C356C
"The Hermit", Reg #4998

Hi Ab
the real men don't even use the screwdrivers just use your fingers and it takes longer to invert it afterwards but you can do it in less time then it takes to answer/read your post.
KTF
jacques

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Since Steve's post was about split boots, I didn't want to drag it too far off topic. I always disassemble the tube, it takes more time but has certain advantages. Dennis did a nice job of explaining the stretch method with his photos.

Photo below is a disassembled tube from Tim McGuire's '59 Cabriolet transmission, which he'll be happy to hear is nearing completion. I should probably photograph the tube assembly process.

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Jon Bunin

I suppose there is merit in what you say if and only if you are a not a speed reader and frequently lapse into writer's block.

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Albert Tiedemann, C356C
"The Hermit", Reg #4998

Hi Ab
early to bed and early to rise and you too can do it
jacques

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Hi Ab
when we do it the Porsche way we give it to "Mikie" the nickmane of our arbor press to get the upright off/ to assemble we just pound the upright on until the hole lines up no special tools needed.
jacques

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A major benefit to disassembling the tube, is that you can check for a bent one by using a long straight-edge. Yes, some tubes are obviously bent and can be seen with the naked eye. But others are only off slightly, and can not be detected with the shock mount on.

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Hi Vic
If the straight edge is a long piece of nice angle iron you can do it from the inside.
jacques

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Let's say someone wanted to replace their boots using solid boots and the stretch method.
Question: What is a good time estimate to remove the axle tube, clean, paint, put on the boot and re-install with all adjustments. Answer for both sides please.

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Hi Paul
What is the initial starting point? Is the tranny still in the car? you have to be careful removing the tube not to have the fulcrum plates slip. changing the boot is trivial compared to the other operations which can be very time consuming unless you want a rattle can job.
jacques

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There used to be a "book time" for estimates like this, but now, 40+ years later, it is what it is, especially if a DIY project.

I have given up on transmission work since my tools went away permanently 'on loan' (and thanks for the offer of replacements years ago, Jon), but never tried the 'solid boot stretch.' Now Vic or Eric Wills get my recommendations for that work (directly) from my east coast customers, depending on customer location.

As I also either never had or 'lost' my press fixtures for such applications, I found that I could drag the bearing housing off the tube end with some heat and a big gear puller pressing on a specially-made tube end plug. After checking trueness and derusting/painting, the end was reinstalled (keep parts together and note what orients where) by dragging back on with proper bushings and a long thick threaded rod. A little green stuff on the pin and all was well.

Going back to the original posting...the split boots have been problematic over the years based on vendor's vendor's supply. Some are great, install easily and don't leak, some don't fit well, fight installation, leak and don't last very long at all. Shopping for the best, not cheapest, boots is the key to success when the trans is not coming apart.

And yes, while SWEPCO trans lube is the best stuff going in most instances, it finds ways to come out just to remind you it's there (and say "Remember me...I'm green!") unlike the old petroleum gear oils.

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Jacques
Starting with trans in the car. Total time estimated.

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Five years ago Alan Klingen installed split boots on my A coupe when he rebuilt the transaxle. They haven't leaked yet.

Barry

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Barry, that's my point exactly. I have done some split boot installations as supplied by a couple of our most well-known vendors with huge differences in fit and quality ....and I hate to say it...."margin," I'm sure. I also hate to say that those differences are not intentional, but a result of the seller not being an installer.

(Maybe you can get Alan to reveal his source? Five years is likely to outlast my career!)

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