Disassembling And Assembling Transmission

Disassembling

Disassembling

Porsche 928 Tool

Always counterhold on interior shift rod with a suitable tool when driving out pins and keys.

Assembling And Disassembling

2. Remove differential (see page 39 - 201).

3. Remove shift rods, shift forks and locks.

Always counterhold on interior shift rod with a suitable tool when driving out pins and keys.

7. Pull out input shaft and bearing cap with Special Tools 9140 and 9148

Always first remove countershaft and lower countershaft to bottom of transmission.

Special Tool Sporsche 928

4. Pull out clamp for reverse gear with a suitable pliers.

5. Unscrew drive pinion mounting bolts, mount Special Tool on bearing assembly and turn until reverse gear shaft can be removed with Special Tool VW 771,

Assembling

1. Screw in preselector spring with stud from inside to outside.

6. Remove circlip for input shaft.

7. Pull out input shaft and bearing cap with Special Tools 9140 and 9148

Always first remove countershaft and lower countershaft to bottom of transmission.

A = Preselector spring

4. Drive in complete input shaft over bearing outer race against stop alternately with a piece of suitable pipe or a mandrel.

Porsche 928 Thrust Bearing

2. Stick thrust washer for countershaft in case with a little grease.

4. Drive in complete input shaft over bearing outer race against stop alternately with a piece of suitable pipe or a mandrel.

B = Thrust washer

3. Place complete countershaft in case.

Porsche 928 Thrust Bearing

5. Insert O-ring for bearing cap and lubricate with a light coat of oil.

6. Mount bearing cap and circlip.

7. Swing transmission on assembly stand to have input shaft face down.

8. Install needle cages and thrust ring in input shaft.

9. Place synchromesh ring for 5th gear on clutch body.

10. Place reverse gear and needle cages in case as shown in the picture.

Clutch Gearbox Porsche 928

A = Special Tool 9321

Porsche 928 Thrust Bearing

10. Place reverse gear and needle cages in case as shown in the picture.

11. Screw centering pins, Special Tools 9321, in case for installation of drive pinion and install shims S3.

12. Mount Special Tool 9144 on drive pinion bearing cap and move in drive pinion carefully (with 4th gear engaged). Check that reverse gear is positioned correctly.

A = Special Tool 9321

When installing the drive pinion make sure that pins of synchromesh ring (5th gear) engage in openings of guide sleeve.

13. Move reverse gear to correct installed position with a suitable tool, remove centering pins 9321 for bearing assembly and turn latter together with shims until the reverse gear shaft can be mounted.

Porsche 928 Thrust Bearing

14. Drive in reverse gear shaft only far enough that thrust washer can be installed. Then drive in reverse gear shaft to correct installed position and install clamp.

Thrust Washer Bearing Installation
2 = Thrust washer

15. Turn bearing assembly and shims S3 to installed position, tighten mounting bolts to torque of 30 Nm and remove Special Toot 9144.

Porsche 928 Thrust Bearing

16. Move countershaft to correct installed position and install shaft with O-ring (O-ring coated lightly with oil).

Note

Facilitate installation by turning transmission on assembly stand until countershaft falls into correct installed position on its own weight.

Porsche 928 Transmission Rebuild

17. Install circlip.

18. Turn on idle.

19. Install shift rods, shift forks and locks.

Porsche 928 Transmission

2 - Shift rods (1st and reverse gears)

3 - Locking sleeve (long)

7 - Locking sleeve (short)

8 - Spring

10 - Shift rod (4th and 5th gears)

11 - Locking sleeve (short)

20. Mount interior shift rod with preselector lever and shift arm, counterholding on shift rod with a suitable tool.

Porsche928 Transmission Mount

Note

Cavity for pointed screw in interior shift rod must face left (in forward direction).

21. Install lockpin in correct position.

Porsche 928 Input Shaft

22. Adjust preselector spring and shift forks (see page 34 - 215).

DISASSEMBLING AND ASSEMBLING MANUAL TRANSMISSION ('87 MODELS ONWARD)

Porsche Manual Transmission Shift
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