Workshop Manual

DR. ING. b.c. F. PORSCHE Aktiengesellschaft

TECHNICAL DATA Front Axle Suspension

Springs Dampers

Make/installation Stabi1izers until end of model year 79 80 models onward 86 models onward

Independent suspension, double control arm with coil spring and internal damper.

1 coil spring per wheel

Double-action hydraulic dampers See page 40 - 51

dia. 26 mm dia. 28 mm x 4 (tubular stabilizer)

dia. 28 mm x 4 {tubular stabilizer) with modified knuckle

TIGHTENING TORQUES FOR FRONT AXLE

Location

Description

Thread

Material

Torque Nm (ftlb)

Upper control arm to body

Self-locking hex nut

VM 14x1.5

8

140 (103)

Lower control arm to body, rear

Hex bolt

M 12x1.5

10.9

120 (88}

Lower control arm to body, front

Hex bolt

M 12x1.5

8.8

85 (62)

Guard to longitudinal member

Self-locking hex nut

VM 10

8

46 (33)

Spring strut to body

Self-locking hex nut

VM 10

8

46 (33)

Spring strut and stabilizer linkage to lower control arm

Self-locking hex nut

VM 12x1.5

8

85 (62)

Stabi1izer clamp to longitudinal member

Hex bolt

M 10

8.8

46 (33)

Stabi1izer linkage to stabilizer

Self-1ocking hex nut

VM 12x1.5

8

85 (62)

Upper and lower control arms to steering knuckle

F1ange 1ocknut

M 12x1.5

8

65 (47)

Guard to steering knuckle

Hex bolt

M 7

8.8

15 (11)

Cable holder to steering knuckle

Hex bolt

M 7

8.8

15 (11)

Location

Description

Thread

Material

Torque Nm (ftlb)

Brake caliper to steering knuckle

Hex bolt Panhead bolt

M 12x1.5

8.8

85 (62)

Brake disk to wheel hub

Countersunk bolt

M 6

8.8

10 (7)

Panhead bolt to clamping nut

Panhead bolt

M 7

10.9

15 (11)

Wheel to wheel hub

Wheel nut

M 14x1.5

Al

130 (95)

Steering track rod to steering arm

Hex nut, self-locking

VM 12x1.5

8

65 (47)

Rubber bushing of piston rod of spring strut

Hex nut, self-locking

VM 12x1.5

8

60 (44)

Ball joint, (mounting) to lower control arm

Hex nut, self-locking

VM 12x1.5

10

120 (88)

Support plate on steering axle {upper control arm)

Hex nut, self-locking

VM 12x1.5

8

85 (62)

Roadspeed sensor to steering knuckle

Panhead bolt

M 6

8.8

10 (7)

NOTES ON FRONT AXLE, 86 MODELS ONWARD New front wheel suspension

Matra V12 Engine

Front Axle Modifications, 86 Models Onward

No./Description

Most Important Modifications

Remarks

1 Steering knuckle

Attachment points for brake caliper

Studs for wheel bearing {clearance and diameter for outer bearing)

Locator for ball joint No. 10 of the mounting

Four-piston fixed caliper, 86 models onward

- Wheel bearing

Outer wheel bearing larger. Distance between bearings increased

Adjust as before (every 20000 km)

- Steering offset

- 10.2 mm before - 16 mm

For braking system (four-piston fixed caliper)

Heights and wheel geometry unchanged

2 Upper control arm

Shorter than before. Ball joint inclined outward

Distinguishing feature, P. 40 - 16/17

3 Dampers

Adjustment

Table P. 40 - 51

(Boge) standard and optional previously standard :

2-pipe pressureless (Boge)

optional :

1-pipe gas-filled (Bilstein)

Combination with coil springs up to 86 models impermissible

No./Description

Most Important Modifications

Remarks

4

Coil springs

spring rate increased

Only for Boge gas dampers.

Combination with dampers up to 86 models or Bilstein dampers impermissible P. 40 - 46

7

Stabilizer 1inkage

longer than before

P. 40 - 16/ 40 - 18

-

Stabilizer

modified knuckle

P. 40 - 16/18

8

Steering track rods

approx. 10mm shorter than before

P. 40 - 16/17

9

Mounting (steel)

upright ball joint (previously trailing ball joint)

P. 40 - 19 to 40 - 21

11

Camber and caster eccentrics (same parts)

external contour smaller

External eccentric A = camber eccentric

Internal eccentric B = caster eccentric

P. 40 - 21

12

Lower control arm

shorter than before

Distinguishing feature/code P. 40 - 16/17

13 Spring strut stirrup

modified mounting point for spring strut, because control arm shorter but strut position same as in cars earlier than 86 models

Distinguishing feature/code P. 40 - 19 to 40 - 21

TOOLS

No.

Description

Special Tools

Remarks

1

Press-out tool

VW 267 a

2

Track rod puller

e.g. Nexus 168 - 1

No.

Description

Removing

Installing

1

Locknut

3

renew, torque: 46 Nm (33 fltb)

2

Washer

3

3

Flange locknut (for steering knuckles without push-off lug for ball joint)

or

2

load ball joint by exerting pressure on upper control arm

renew, torque: 65 Nm (47 ftlb). Exert pressure on upper control arm to load ball joint

3a

Flange locknut Cap locknut (on steering knuckles with push-off lug for the lower ball joint). (See page 40-25)

1 1

4

Locknut

2

to ease installation, see removing as for 86 models onward (p. 40 - 8)

renew, torque: 140 Nm (103 ftlb)

5

Washer

1

only on rear pin of control arm

Washer, 928 S only (floating caliper brake)

Air guide plate, 928 S (floating caliper brake)

1

renew, torque: 85 Nm (62 fltb)

No.

Description

Removing

Installing

7

Hex bolt

1

8

Stabi1izer 1inkage

1

when replacing, do not confuse with version for 86 models onward. Installation overview, pages 40 - 16 to 40 - 18

9

Upper control arm

1

inspect, renew if necessary, reworking is impermissible

10

Spring strut

1

11

Steering knuckle

1

inspect for damage, reworking is impermissible See page 40 - 25

12

Locknut

2

renew, torque: 120 Nm (88 ftlb)

13

Caster/camber eccentrics

1

lubricate sliding suf-faces of eccentric adjustment range with Optimoly TA. Cover ball joint slots. See pages 40 19, 40 - 20 and 40 - 23

14

Camber/caster eccentric

1

see pages 40 - 19 and 40 - 20 for position and types.

15

Ball joint (mounting)

1

inspect, renew if necessary. Cover slot, see pages 40 - 19, 40 - 20 and 40 - 23

No.

Description

Remov i ng

Instal1ing

16

CI amp

1

see pages 40 - 19 and 40 - 20

17

Locknut

2

renew, torque: 46 Nm (33 ftlb)

18

Hex bolt

2

(10.9, 80 mm long)

2

Coat threads with Optimoly HT (do not apply Optimoly HT to bolt shank).* Screw in until only 2 threads are visible. Do not tighten to 120 Nm (88 fltb) until assembly is completed and springs have settled

20

Washer approx. 6 mm thick, dia. approx. 30 mm

2

do not mix up with washer No. 23

21

Bearing clamp

1

inspect for damage. Tighten to specified torque

22

Hex bolt (100 mm long)

2

Coat thread with Optimoly HT. (Do not apply Optimoly HT to bolt shank).* Torque: 85 Nm {62 ftlb)

No.

Description

Removing

Instal1ing

23

Washer approx. 4 mm thick dia. approx. 25 mm

2

do not mix up with washer No. 20

24

Guard

1

spoiler securing bolts cup washers securing brackets locknuts

1

renew if damage suspected. No reworking is permissible. Tighten bolts No. 19 of bearing clamp No. 21 as specified. When replacing, do not confuse with control arm for 86 models onward. Installation overview, Pages 40 - 16 to 40 - 18

* 928 S only (floating caliper brakes)

No.

Description

Removing

Instal1ing

1

Locknut

3

Renew, torque: 46 Nm (33 ftlb)

2

Washer

3

3

Speed sensor with 0-ring and mounting bolt

1

coat speed sensor and hole in steering knuckle with Molykote Longterm 2. Renew 0-ring of speed sensor. Tightening torque for Allen-head bolt 10 Nm (7 ftlb)

4

Hex bolt with spring washer

1

5*

Flange locknut

1

If necessary, load ball joints by exerting pressure on upper control arm

renew, torque: 65 Nm (47 ftlb). Load ball joints by exerting pressure on upper control arm

6

Flange locknut

1

As No. 5

As No. 5

7

Steering knuckle

1

inspect for damage. No reworking is permissible.

8

Locknut

2

If necessary (to increase working space), remove bearing clamp No. 25 of lower control arm. When removing bearing clamp, slacken lock-nuts No. 17 on caster and camber eccentrics.

renew, torque: 140 Nm (103 ftlb)

* There is no difference between No. 5 and No. 6 (collar dia. approx. 24 mm). In some cars, a nut (No. 5) with a collar dia. approx. 26 mm was fitted to the upper joint (to use up stock).

No.

Description

Removing

Instal1ing

9

Washer

1

only on rear control arm mounting

10

Locknut

1

renew, torque: 85 Nm (62 ftlb)

11

Washer

1

12

Air guide plate

1

13

Hex bolt

1

14

Stabilizer linkage

1

when replacing, do not confuse with version for cars earlier than 1986. Spare part number on linkage.

Tightening torque for upper and lower mountings : 85 Nm (62 ftlb).

Install right way round. Cranked end at top (at spring strut mounting) and tilted forward (no difference bewteen left-hand and right-hand parts).

15

Upper control arm

1

inspect, renew if necessary. No reworking is permissible. Attachment to body: lubricate thread and shank with Opti-moly HT.

16

Spring strut

1

Coil spring page 40-46 Damper installation overview, page 40-51

No.

Description

Removing

Installing

17

Locknut

2

only slacken if part of control arm with clamp and ball joint (mounting) must be replaced

renew, torque: 120 Nm (88 ftlb)

18

Caster or camber eccentric {outer eccentric - camber

2

coat sliding surfaces of eccentric adjustment range with Opti-moly TA.

Cover slots of ball joints, page 40 - 23. When replacing, note page 40-21.

19

Ball joint (mounting)

1

inspect, renew if necessary. Close slot, page 40 - 23

20

Clamp

1

when replacing, do not mix up with version for cars earlier than model year 86. See page 40-21. After inserting in lower control arm, coat thread with Optimoly HT. Do not allow Optimoly HT to touch shank of bolt or to penetrate hole in light-alloy member (see page 40 - 14).

21

Locknut

2

renew, torque: 46 Nm (33 ftlb)

22

Hex bolt

2

No.

Description

Removing

Installing

23

Hex bolt (10.9/ 80 mm long)

2

coat thread with Opti-moly HT (Optimoly HT on bolt shank is impermissible).* Screw in until only 2 threads are visible. Do not tighten to 120 Nm (88 ftlb) until assembly is completed and springs have settled.

24

Washer approx. 6 mm thick, dia. approx. 30 mm

2

do not mix up with washer No. 27

25

Bearing clamp

1

check for damage. Tighten as specified.

26

Hex bolt (100 mm long)

2

coat threads with Optimoly HT (Optimoly HT is not permissible on bolt shank)* Torque: 85 Nm (62 ftlb)

27

Washer approx. 4 mm thick, dia. approx. 25 mm

2

do not mix up with washer No. 24

28

Guard

1

No.

Description

Removing

Installing

29

Lower control arm with spoiler securing bolts cup washers securing brackets locknuts

1

Renew if damage suspected. No reworking is permissible. Tighten bolts No. 23

of bearing clamp No.

25 as specified.

When replacing, do not mix up with control arm for cars earlier than model year 86. Part marked "Porsche" (before 86 model years, without Porsche inscription). Installation overview, see pages 40 - 16/ 40 - 17

INSTRUCTIONS FOR ASSEMBLY AND DISASSEMBLY

3.Press out track rod with extractor, e.g. Nexus 168-1.

2.Disconnect ground lead (86 models onward). Remove speed sensor.

Mounting: 86 models onward

1.Unbolt brake caliper and move aside without imposing strain on brake hose.

Mounting: until end of model year

Mounting: 86 models onward

Beforehand, open plug-in connector of ABS and brake-pad wear cable and disconnect.

2.Disconnect ground lead (86 models onward). Remove speed sensor.

3.Press out track rod with extractor, e.g. Nexus 168-1.

4.Use VW 267a to press out ball joint. Take care not to damage protective caps of joints. (Steering knuckle with cap nut, see page 40 - 25). If collar nuts difficult to remove, see Installing, Item 3.

Wheel suspension, 86 models onward (lower bal1 joint).

When using Optimoly HT or TA assembly paste, note the following:

Optimoly HT (copper-colored)

For steel-steel threaded connections and contact surfaces of assembly parts.

Never use Optimoly HT on contact surfaces of steel to light alloy, as moisture will produce corrosion. When applied to threads, this lubricant has no effect on tightening torques.

Optimoly TA (aluminum color)

For all connections with aluminum or with magnesium, for corrosion protection.

When applied to threads, this lubricant has a slight effect on tightening torques.

1.Subject all parts to visual inspection, if necessary, compare with new part.

If replacement parts are fitted, check installation overview, see pages 40 - 16 to 40 - 21

2.When installing lower control Close slots for outer cams (page arm, screw bolts of rear bearing 40 - 23). clamp into body until only 2 threads are visible.

Do not tighten the two bolts to _

specified torque until assembly is completed and springs have settled. This keeps front of car down.

3.To prevent ball pins turning and to allow installation of collar nuts (also for disassembly), apply pressure to upper control arm to load ball joints.

Note:

Spray adjustment plate on lower control arm with eccentrics, threaded section of track rod, threaded pins in upper bearing joint and threaded pins in lower bearing joint with Tectyl-UL 846 (Valvoline). This prevents corrosion of the threaded elements, thus facilitating maintenance and repair work.

WHEEL SUSPENSION COMPONENTS - INSTALLATION OVERVIEW*

Identification - Distinguishing Features**

Fig. No.

Description

Version A until end of model year 85

Version B 86 models onward

1

Upper control arm

longer than 86 models onward, ball joint at right angle to suspension link

shorter than until end of model year 85, ball joint inclined outward

2

Lower control arm

longer than 86 models onward, no identification marking

shorter than until end of model year 85, bears "Porsche" inscription

3

Track rod

longer than 86 models onward

shorter than until end of model year 85

4

Stabilizer linkage

shorter than 86 models onward, marked with sparepart number

longer than until end of model year 85, marked with spare-part number

5

Stabilizer

stabilizer knuckle shorter and less cranked than 86 models onward (until end of model year 79, solid stabilizer, 80 models onward, tubular stabilizer)

stabilizer knuckle longer and more cranked than until end of model year 85

* Mounting, clamp, camber and caster eccentrics, pages 40 - 19 to 40 - 21

* Mounting, clamp, camber and caster eccentrics, pages 40 - 19 to 40 - 21

2 Lower control arm

Porsche 928 Lower Control Arm Bushings

Version A

until end of model year 85

Version B 86 models onward

1 Upper control arm

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