Technical Data Rear Axle

Wheel suspension Independent wheel suspension with lower diagonal suspension links and upper wishbones, coil springs and interna! dampers.

Springs

1 coil spring per wheel

Dampers Make/Installation double-action hydraulic dampers page 42 - 18 d

Stabilizers

0 21 mm

0 22.5 x 3.5 mm (tubular stabilizers) modified in course of model year 1981

Spacers standard up to end of MY '91 "Club-Sport"-Version standard as of MY '92

17 mm per wheel 38 mm per Rad

Technical Data

Printed in Germany - XXIX, 1992

42-01

TIGHTENING TORQUES FOR REAR AXLE

Location

Description

Thread

Material

Torque Nm (ftlb)

Tranverse member to body

Hex bolt

M 10

8.8

46 (33)

Light alloy casting {suspension link bearing) for lower control arm (86 models onward) to body

Hex bolt

M 10

46 (33)

Lower suspension link to transverse member (camber eccentric)

Locknut

VNM 14 x

1.5

10

200 (146)

Lower suspension link to body or light-alloy casting (track eccentric)

Locknut

VNM 12 x

1.5

10

120 (88)

Bearing link to lower suspension link

Locknut

VNM 12 x

1.5

8

85 (62)

Brake caliper to wheel carrier

Hex bolt

M 12

x 1.5

8.8

85 (62)

Wheel carrier to lower suspension 1 ink

Locknut

VNM 14 x

1.5

8

140 (103)

Upper suspension link to transverse member, upper suspension link to wheel carrier

Locknut

VNM 10

8

46 (33)

Propshaft or rear axle to wheel hub

Locknut

VHM 22 x

1.5

8

460 (322)

Propshaft to differential and input shaft

Cap bolt

M 10

12.9

81 (59)

Wheel to wheel hub

Wheel nut

M 14

x 1.5

AL

130 (94)

Spring strut to body

Locknut

VNM 10

8

46 (33)

928

Rear Wheel Suspension,

Propshaft

42

Location

Description

Thread

Material

Torque Nm (ftlb)

Rubber bushing on piston rod (spring strut)

Locknut

12 x 1.5

8

58 (42)

Transmission bearing to rear-axle transverse member

Hex bolt

M 12 x 1.5

8.8

85 (62)

Stabilizer bearing to body

Hex bolt

M 10

8.8

46 (33)

Stabilizer linkage to lower suspension link

Hex bolt

M 10

8.8

46 (33)

Stabilizer linkage to stabilizer

Locknut

VNM 10

8

46 (33)

Speed sensor to wheel carrier

Cap bolt

M 6

8.8

10 (7)

Angle bracket to wheel carrier

Hex bolt

M 6

8.8

10 (7)

Angle bracket to transverse member

Locknut

VM 6

6 (4)

Guard to wheel carrier

Locknut Hex bolt

VEM 8 M 6

8 8.8

23 (17) 10 (7)

TOOLS

No.

Description

Special Tool

Remarks

1

Punch

VW 407

2

Thrust plate

VW 402

3

Tube

VW 415 a

4

Punch

VW 408 a

5

Support ring

VW 440

6

Thrust tube

VW 455

7

Remover/installer

VW 459/2

Part of VW 459

8

Thrust tube

P 263

Disassembling and Assembling Rear Suspension 42-1

42-2 Disassembling and Assembling Rear Suspension

Printed in Germany

No.

Description

Qty.

Note When Removing Installing

Special Instructions

1

Self-locking nut

1

Replace if necessary. Tighten to specified torque

2

Washer

1

3

Socket head bolt

6

Tighten to specified torque

4

Axle shaft

1

Check for damage

5

Locknut

3

Replace, tighten to specified torque

C

Washer

1

Plug

1

8

Cover

1

3

Lock nut

2

Replace, tighten to specified torque

10

Washer

2

11

Pivot pin

1

12

Washer

1

13

Cone washer

2

14

Spring strut

1

If necessary, replace seal on mounting plate

15

Locknut

2

Replace, tighten to specified torque

1G

Cone washer

1

17

Bolt

1

IS

Cone washer

2

20

Hub assembly Bolt

1

Straightening not permitted

Printed in Germany - VII, 1983

Disassembling and Assembling Fear Suspension

42-3

No.

Description

Qty.

Note When: Removing Installing

Special Instructions

21 22

Upper control arm Upper arm mount

2

Position correctly

Straightening not permitted

23

Bolt

1

Tighten to specified torque

24

Washer

2

25

Locknut

1

Replace and tighten to specified torque

26

Bolt

1

27

Stabilizer suspension

1

Check for damage

page 42 - 6

28

Locknut

1

Tighten to specified torque

29

Eccentric disc

1

30

Eccentric bolt

1

31

Locknut

1

Tighten to specified torque

32

Washer

1

33

Eccentric bolt

1

Lubricate with MoS2 grease

35

Lower control arm Locknut

Replace and tighten to specified torque

Left and right sides not interchangeable, welding and straightening not permitted

36

Washer

2

Replace if necessary

37

Bolt

1

38

Mount

1

Position correctly

39

Rubber mount

1

page 42 - 6

40

Rubber mount

2

page 42 - 6

42-4 Disassembling and Assembling Rear Wheel Suspension VII J, 1984 - Printed in Germany

5.Remove wheel carrier.

NOTES ON DISASSEMBLY AND ASSEMBLY

Disassembl ing

¡.Remove propshaft with drive shaft.

5.Remove wheel carrier.

2.Remove brake caliper.

3.Take off brake disk after removing two countersunk screws.

4.Remove parking brake shoes and expansion lever. Pull parking brake cable out of its guide in wheel carrier.

6.Unscrew eccentric bolts and stabilizer linkage bolt and remove lower diagonal suspension 1 ink.

Notes on Wheel Suspension, 86 Models Onward.

The exhaust system has been modified as of model year 86. Two secondary mufflers are mounted near the control arms, one on each side.

This modification has necessitated modification of the following components:

- Rear axle transverse member

- Bearing link of lower suspension link mounted on a removable light-alloy casting (instead of directly on body).

- The length of the track eccentric bolt (2) has been changed to suit the modified bearing (bolt shank approx. 10 mm longer).

2.Coat shanks of camber and track eccentric bolts with Optimoly TA (instead of multi-purpose grease with MoS^) and coat thread with Optimoly HT. Apply a coating of Molykote U to rubber bushing of stabilizer linkage and rubber bushings No. 39 and 40 of lower control arms (page 42-2) before installing suspensions links in car.

See Table of Consumables (Technical Information Group X) for further lubrication notes and specifications.

Note:

Spray toe-in eccentrics and camber eccentrics on both sides, adjustment for spring plate on damper and ends of bearing bolt threads (wheel carriers) with underbody wax such as Tectyl - UL - 846 manufactured by Valvoline. This precaution prevents corrosion of the threaded connections, thus facilitating future maintenance and repair work.

3.Tighten bolts and nuts to specified torque.

4.Align axles.

Assembling

1.Inspect parts for damage, compare suspect parts with new parts. Do not mix up left-hand and right-hand lower diagonal suspension links (otherwise spring travel is impaired).

TOOLS

No.

Description

Special Tool

Remarks

1

Punch

VW 407

2

Base plate

VW 441

3

Drive sleeve

VW 244 b

4

Tube

VW 415 a

5

Extractor

-

Standard

No.

Description

Qty-

Note When liemoving Installing

Special 1

Instructions

1

Self-locking nut

1

Replace if necessary, tighten to specified torque

9

Washer

1

Socket head bolt

G

Tighten to specified torque

4

Axle shaft

1

Check for damage

5

Wheel hub

1

Press off with Press on with VW 244 b and VW 244 b, whereby suitable base ball bearing inner plates race must be on VW 415 a

6

Circlip

1

Replace if necessary

1

Brake backing plate

1

Insert wheel hub in ball bearing before pressing in

8

Bali bearing

1

Heat hub carrier Heat hub carrier to to 120 - 150° C 120 - 150° C (248 -(248 - 302° F), 302° F). Install new Press out with bearing. Place VW 415 a VW 441 underneath hub carrier and press on lightly with VW 415 a, being careful that inner races do not fall out

9

Hub carrier

1

10

Gasket

1

Replace

1. Press out wheel hub with VW 244 b and suitable base plates.

2. Remove circlip.

4. Press bearing inner race off of wheel hub with an extractor and Special Tool VW 407.

3. Press out ball bearing with VW 415 a after heating hub carrier to 120 - 150° C (248 -302° F).

Assembling

1. Heat hub carrier to 120 - 150° C (248 - 302° F), install ball bearing and then pres on slightly.

2. Press in wheel hub after installation of circlip and brake backing plate.

REPLACING LOWER DIAGONAL CONTROL ARM LINK PIN

1. Remove boit "from link pin.

2. Place lower control arm on Special Tool VW 402. Press out link pin with Special Tool VW 407.

1. Coat holder and link pin with waxfree Capella Oil B (Texaco). Install link pin by hand so that bend of link pin faces in toward lower control arm and holes for mounting bolt are aligned.

2. Press in link pin far enough so that bolt can be installed without applying force.

Rubber mounts used for lower control arms have a long service life, but if they do have to be replaced this can be accomplished with the following tools and application of waxfree Capella Oil B.

Rubber mount for pivot pin of shock absorber and hub carrier

Rubber mount for camber eccentric bolt

Removal

First press out inner metal bushing.

VW 402 VW 407

Installation

VW 459/2 VW 455

Make sure that inner bushing is not displaced.

VW 402 VW 407

REPLACING UPPER CONTROL ARM MOUNT

Removing

Installing

Press out mount with Special Tool VW 408 a, using Special Tool VW 415 a as a base.

Press in mount, using waxfree Capelia Oil 8 (Texaco) and Special Tools VW 415 a and 408 a. Position correctly. Apply pressure pad to conical end of metal bushing to prevent any change in position between the metal bushing and rubber mount.

REMOVING AND INSTALLING SPRING STRUT

Removing

1. Unscrew three self-locking nuts from spring strut in luggage compartment.

2. Remove wheel.

3. Unscrew front nut on pivot pin of lower control arm, counterlocking and counter-holding the rear nut with a separate

4. Disconnect stabilizer bar link at control arm.

Installing

1. Replace self-locking nuts. Check spring strut seal, making a new permanently elastic seal on the mounting plate 300mm long and circular in shape with, for example, Prestik 4 mm dia., Item No. 0593 from Bostik. Coat rubber mount on mounting eye with Molykote U.

2, Tighten to specified torques.

3. Note installed position of lower shock absorber.

Note

Turn lower shock absorber to correct position with a hook wrench applied to adjusting nut.Select direction of turning so that stop of spring retainer remains on end of spring. Further the adjusting nut must not be turned against the threaded sleeve, so that the car height adjustment is not changed.

TOOLS

No.

Description

Special Tools

Remarks

Tensioning device

VW 340

Porsche version by Klann, see Workshop Manual (Workshop Equipment 3, group 4) for description/ supplier.

2

Sickle wrench DIN 1810 dia. 80/90

commercially available, e.g. Saltus

928

Rear Wheel Suspension

, Propshaft 42

No.

Description

Removing

Installing

1

Locknut

3

renew, torque: 46 Nm (33 fltb)

2

Washer

3

3

Cover

1

4

Dirt excluder

1

5

Locknut

1

Stretch coil spring with VW 340 or Klann KL - 0014

renew, torque: 58 Nm (42 ftlb)

6

Washer

1

7

Mounting plate

1

8

Rubber support

1

coat with Molykote U

9

Damper bushing

1

coat with Molykote U

10

Support plate

1

see note on page 42 - 18c

11

Spring plate

1

see note on page 42 - 18c

12

Coil spring

1

note allocation, tolerance group and remarks on page 42 - 18b/c

13

Protective tube

1

No.

Description

Removing

Instal1ing

14

Circlip

1

15

Secondary spring

1

Check installation position

16

Stop

1

Install with grooves down

17

Lower spring plate

1

Coat contact surface for adjuster nut with Optimoly TA. Note remarks on page 42 - 18c

18

Support cover

1

Boge only

19

Threaded sleeve

1

Coat thread with Optimoly TA. See remarks on page 42 - 18c

20

Adjuster nut

1

Check freedom of movement (to facilitate adjustment). Boge and Bilstein are different. See remarks on page 42 - 18c

21

Damper

1

Check efficiency, renew if necessary. Modified dampers as of model year 86. Damper installation overview, page 40 - 18d

NOTES ON DISASSEMBLY AND ASSEMBLY

Disassembl ing

1.Using Porsche-version Klann spring tensioning device (see Workshop Manual) or VW 340, stretch coil spring. Remove self-locking nut from piston rod. Remove mounting plate with support plate.

VW 340

Testing Dampers

Dampers can only be tested properly on a test bench. Although inefficient dampers cannot be identified, a visual inspection or check of operation will identify completely defective dampers.

Note:

Distinguishing features of dampers, see page 42 - 18d.

Boge Dampers, Pressurel ess

With damper in installation position, extend and compress by hand. The damper must move smoothly and with uniform resistance through its entire travel. The extension and compression-stage damping must be-felt clearly-right up to the-final positions. Dampers which have been stored for an extended period of time should be pumped in and out several times in the installation position. Replace leaking dampers.

Boge Gas Pressure Dampers

With damper in installation position, extend and compress by hand. Damper must move smoothly throughout its travel. Extension and compression-stage damping must be felt clearly right up to final positions. Because of the gas pressure, the resistance of the

2.If special tool VW 340 is used, relax tension on coil spring by screwing down each of the clamping bolts in turn.

piston rod increases as the rod moves into the damper. If dampers have been stored for a long time, pump in and out several times in installation position.

Replace leaky dampers.

If dampers have depressurized (damper does not return automatically to expansion-stage and stop), but show no signs of escaping oil (oil stain) and fulfill the remaining requirements, they can be reused. Dampers which show traces of oil leaks and have lost their gas pressure must be replaced.

Bilstein Dampers

Worn Bilstein dampers can be readily identified.

Measure dimension X with damper completely compressed (i.e. as far as possible). If dimension X is larger than 18 mm (new damper 8.5 mm), the damper must be replaced.

Assembling

Rear-axle springs are available in three versions. The versions are color-coded.

The springs with green, yellow and blue coding are further subdivided in tolerance groups.

When replacing, always install springs with the same color coding. Under no circumstances may yellow, green and blue springs be combined.

As car height is adjustable, it is not necessary to correlate spring groups with certain model types (e.g. with or without air conditioner, left-hand or right-hand drive).

Coil spring (green)

928, until end of model year 78

Part No. 928.333.531.09

Gr.

F where L1 = 272 mm

Color code

Ordering I ndex

1

4719...4817

N

1 green

201

2

4818...4915

N

2 green

202

3

4916...5013

N

3 green

203

Coil spring (yellow) 928/928 S from 79 models until current 84 model year (see note below), Part No. 928.333.531.12

Gr.

F where L. = 253.5 mm

Color code

Order index

1

4710...4810

N

1 yellow

101

2

4811...4910

N

2 yellow

102

3

4911...5010

N

3 yellow

As of the following chassis numbers:

92 ES 840 416 928 S Europe/r.o.w 92 ES 849 568 928 S Japan 92 ES 860 562 928 S USA

in the current 84 model year, the coil springs, both spring plates of the supporting plate and the adjuster nut with threaded sleeve have been modified to reduce weight.

Coil spring (blue)

928 S, installed in the current 84

models as of the chassis numbers listed above, Part No. 928.333.

531.14.

Gr.

F where L-

Color

Order

249.8 mm

code

index

1

4680...4800

N

1 blue

301

2

4801...4920

N

2 blue

302

3

4921...5040

N

3 blue

303

DAMPERS - INSTALLATION OVERVIEW, IDENTIFICATION AND DISTINGUISHING FEATURES

Front axle

Non-adjustable front-axle spring strut

Re

ar Si

axl ngl Do

e e p ubl Pr

ipe e p ess Ga

ipe ure s p Bo

les res ge Bi

s sure lstein

Paint coding, Identification

928/928 S standard

X

0

X 0

X 0

X 0

black* black**

928/928 S optional extra

X

0

X 0

X 0

X 0

green green

Adjustable front-axle spring strut

928 S standard until end of model year 85

X

0

X 0

X 0

X 0

black* black**

928 S optional extra until end of model year 85

X

0

X 0

X 0

X 0

gold gold

928 S standard 86 models onward

X

0

X 0

X 0

X 0

grey grey

928 S optional extra 86 models onward alternative

X X

0 0

X 0

X 0

X 0 X 0

X 0

X 0

red red gold gold

Optional Extra = Sport Tuning

When removed, the pressureless damper will remain in any desired position. When the gas pressure damper is removed it extends to the expansion stage stop.

REMOVING AND INSTALLING AXLE SHAFT

Axle Shaft Bolted on Both Sides Removing

1. Remove cylinder head bolts on transmission and wheel ends.

Axle Shaft Welded on One Side Removing

1. Remove socket head bolts on transmission end and self-locking nut on wheel end.

Note:

Self-locking nut is accessible after removing wheel cover.

Wheels do not have to be removed.

2. Run out axle shaft on right and left sides toward inside.

Lower rear end of exhaust assembly on left side.

1. Run axle shaft into wheel hub on wheel end (lubricate splines and threads with Optimoly HT).

2. Install socket head bolts on transmission end (axle shaft flange surfaces must not have grease).

3. Tighten socket head bolts to 83 Nm and self-locking nut to 460 Nm.

2. Run out axle shaft on righthand side toward inside.

3. Run out axle shaft on lefthand side toward outside, after removal of rear wheel. Make sure that grease from constant velocity joint does not come on brake disc.

Installing

Clean axle shaft flange surfaces to remove grease. Tighten bolts to 83 Nm.

Printed in Germany - VII, 1983

Removing and Installing Axle Shaft

TOOLS

No.

Description

Special Tool

Remarks

1

Circlip pliers

VW 161 a

2

Punch

VW 408 a

3

Plate

VW 401

4

Sieeve

VW 455

No.

Description

Removing

Installing

Special Instructions

1

Circlip

2

Replace, make sure of correct fit

2

Constant velocity joint

2

Pack 80 grams of grease in each joint groove on outside diameter of joint to outside of propeller shaft.

Grease quantity only valid for joints

Only special grease (spare part delivery)

3

Gasket

2

Replace

4

Sealing flange

2

Bearing surface must be grease free

5

Clamp

2

6

Clamp

2

Cut open with side nippers

Install clamps betweer machined shoulders

8

Dust boot Shaft

2 1

Replace, if necessary Check runout

Axle shafts with welding on one side are installed since 1982 models. The transmission end shaft is still bolted as before . while on the weel end the axle shaft and drive shaft are welded. Welded axle shafts can also be installed retroactively in older models. Bolted axle shafts on both ends, however, cannot be installed in cars after 1982 models on (would scrape on wheel carrier)

Dust Cover Versions

The welded axle shaft has a different dust cover with improved sealing. The dust cover has a bead (arrow) and the sealing flange a groove.

A For bolted axle shaft on both ends B For welded axle shaft on one end

DISASSEMBLING AND ASSEMBLING AXLE SHAFT

Disassembling Assembling

1. Clamp axle shaft in a vise fitted with soft 1. Seal large diameter end of new dust boot with jaws. an adhesive. This requires that seats of sealing flange and boot be clean and free of grease. Adhesive: 3 M Scotch Seal 750 (available in 5 oz. tubes)

2. Remove clamp and push dust boot with sealing flange toward inside of axle shaft,

2. Squeeze new clamp with a special pliers, e.g. VW 1275, between machined shoulders

3. Remove circlip. of sealing flange.

3. Replace gasket on flange cover.

4. Push dust boot with sealing flange on to shaft

5. Pack constant velocity joint from each side with approx. 40 grams of special grease uniformly. Total quantity of grease: 80 grams. Special grease is only for joint. Never use grease in dust cover.

80 grams of special grease is delivered with each spare dust boot and each spare constant velocity joint.

4. Press off constant velocity joint using special tools VW 401 and VW 408 a.

1. Swing out ball hub and ball cage from joint and press out in direction of arrow.

6, Position dust boot correctly. Install lamp.

Press constant velocity joint on to shaft. Installa Disassembling and Assembling Constant new circlip. Velocity Joint

Joint must be disassembled to replace grease when seriously contaminated or when bearing surfaces and balls have to be inspected for wear or damage.

1. Swing out ball hub and ball cage from joint and press out in direction of arrow.

6, Position dust boot correctly. Install lamp.

Note

Ball hub and joint are paired. Don" i mix them up. The 6 balls for each joint also belong to one tolerance group.

4. Install huh with cage and balls in joint pointing up. Wake sure that after swinging in hub into joint one wide ball groove "a" on joint is together on one side with a narrow groove "b" of hub.

4. Install huh with cage and balls in joint pointing up. Wake sure that after swinging in hub into joint one wide ball groove "a" on joint is together on one side with a narrow groove "b" of hub.

2. Tilt ball hub out of ball cage via ball groove (arrows).

Assem bling

1. Check joint, ball hub, ball cage and balls for pitting and scoring. Excessive radial play in joint will be noticed by knocking noises when accelerating/decelerating. Replace joint in such a case. Slight wear spots and tracks of balls are no reason to replace joint.

2. Place ball hub in ball cage. Any installed Note position is okay,

Groove of ball hub and running around periphery of outside diameter on joint must face end of axle

3. Press balls into cage, shaft.

5. Swing in ball hub with cage. To accomplish this, swing out hub from cage so far that balls are at same distance as orbits (arrows).

7. Check function of joint. Constant velocity joint has been assembled correctly, if ball hub can be pushed back and forth by hand over the entire axial compensation distance.

6. Press hub with balls into joint (arrow).

REMOVING AND INSTALLING REAR AXI E

Removing

1. Unscrew M 10 self-locking nuts (3 per side) from spring struts in luggage compartment. Remove rear wheels.

?.. Disconnect parking brake cable :t connecter and puit bac!< on) f guitM .

3. Detach brake calipers and suspend from piece of wire. Be sure that brake noses are not too tight.

4. Remove exhaust system as far as necessary depending on version.

5. Disconnect axle shafts at transmission and suspend from wire in horizon)al position on rear axle cross member.

6. Disconnect stabilizer at lower control arm.

7. Support transmission from stabilizer bar with special tool US 8031.

Printed in Germany - iv, 1980 Removing and Installing Rear Axle Assembly 42 - 29

Rear Wheel Suspension, Axle S h a f !

Note

*. Unscrew two mounting bolts of rear axle cross member as well as two bolts of transmission mounts.

Note

Since shims are installed between transmission mounts and the rear axle cross member, note quantity, thickness and location for installation later.

9« Mark position of floe) eccentric bolts. Remote bolts from rear axle cross member.

10. Place floor jack underneath rear axle cross member. Mark position of rear axle cross member. Remove remaining 4 bolts of rear axle cross member.

11, Lower rear axle carefully and be careful not to twist the spring struts, control arms or rear axle cross member.

1, Check spring strut seal (seal between mounting plate and body), tf necessary, make a ne^ permanently elastic seal, e.g. 4 mm dia. Presik, Hem No. 0593 from Bostik. 300 mm long, circle-shaped, on the mounting plate.

2. Move in rear axle. Install mounting bolts and align axle to original position as marked. Tighten bolts to specified torque.

3. Align transmission suspension (see point 8,). Refer to Group 34 if transmission suspension has to be completely aligned, using new parts.

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