Clutch crossshaft bearing update hydraulic operated clutch

On G50 transmission built before April 6,1989, the clutch cross-shaft should be converted to the updated cross-shaft and release fork assembly. The cross-shaft update should be made whenever transmission or clutch repairs are being performed.

On transmissions built from April 6, 1989, this update was part of the factory production.

Clutch Cross-shaft Update Required

• Standard differential up to 950/01 1K 03381

• Limited-slip differential up to 950/01 2K 01159

The cross-shaft update consists of cutting the bearing bores using a special cutter and installing needle bearings into the case. This update requires the following replacement parts:

Parts Required for Cross-shaft Update

Qty.

Description (no. in illustration)

Number

1

Bolt (1)

N 010 287 1

1

Bracket (2)

950 116 713 02

1

Cover (3)

950 116 725 00

1

Bearing (4)

999 201 339 00

1

Release shaft (6)

950116 710 04

2

Seals (5)

999 113 418 40

1

Release fork (7)

950 116 086 05

1

Bearing (8)

999 201 365 00

— Special tools are required to update cross-shaft assembly:

Tools Required for Cross-shaft Update

• Special cutter kit #9292 (Porsche ordering #000 721 929 20)

• ATF lubricant

• Long life bearing grease (Olista® Longtime 3 EP) (Porsche ordering #000 043 024 00)

• Electric drill (variable speed)

— Remove engine and transmission, and separate transmission from engine as described in 101 Engine Removal and Installation.

— Remove clutch release fork from release bearing. Discard release fork and cross-shaft.

— Cut/drill cross-shaft bores in transmission case to accept new bearings:

• Assemble 9292 cutter.

• Use ATF to lubricate cutter and cross-shaft bores in transmission case.

• Set electric drill speed to approximately 500 rpm.

• Slide 9292-3 guide pin into shaft bores in case and cut outer shaft bearing bore (A).

• Change guide pin to 9292-2 and cut inner bearing bore (B). Stop when cutter reaches bottom (increased resistance is noticed).

• Remove burrs from bearing bores. Clean clutch bell-housing.

— Lubricate new cross-shaft bearings with a long life grease. Place inner bearing on cross-shaft and install new bearing into inner bore in case.

^ Install clutch fork on release bearing and hold in place with adhesive tape.

— Assemble transmission and engine.

— Install seal on each end of new cross-shaft. Lubricate outer cross-shaft bearing and install on cross-shaft.

Check seal direction. Refer to instructions with tool kit.

— Thread 6 mm nut approx. 15 mm onto M6X80 bolt.

— Screw 6 mm bolt into threaded end of cross-shaft until nut seats against bearing.

— Insert cross-shaft through bore in transmission case and clutch release fork.

It may be necessary to lightly tap the end of the bolt in order to start the cross-shaft into the release fork.

Porsche 944 Clutch Fork Shaft

0018910

— Remove 6 mm bolt. Remove tape holding release fork in place.

— Lubricate outer cross-shaft bearing and install in transmission case.

— Install rubber bearing cover.

— Place cross-shaft bracket in position and install 6 mm bolt.

Tightening torques

• Cross-shaft bracket to transmission case 9 Nm (80 in-lb)

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