Info

911 Can-era 2 Manual Transmission, Controls, Case When the selector rods are installed, springs (No.2) are under tension install in correct position, use mandrel (dia. 8 mm) to secure to tensioning plate bore Free length 33.9 + 0.5 mm, wire thickness 1.6 mm. Do not confuse with spring no. 12 thickness 1.5 mm. Do not confuse with spring no. 11 Install in correct position, use mandrel (dia. 8 mm) to secure to tensioning plate bore Press in to stop with suitable drift 911 Carrera 2 Manual...

Disassembling and assembling gearbox

Synchronizing Gear Box Assemble Photos

911 Carrera 4 Manual Transmission, Controls, Case 911 Carrera 4 Manual Transmission, Controls, Case Notes on disassembling and assembling 1. Pull cylindrical-roller bearing and needle-bearing sleeve from the hollow shaft with Special Tool 9284. Always use Special Tool 9284. If the drive pinion is used as a support, this may cause damage to the gear wheels in the transmission. 1. Adjust shift fork for 5th and reverse gear Secure hollow shaft with Special Tool 9286 and or 9286 1. Insert shim s...

Transfer case disassembling and assembling

Porsche Rear Axle Assemblies

911 Carrera 4 Manual Transmission, Controls, Case Oil lightly and press in with a suitable tube e.g. VW 418 A , noting correct position Press in with special tool 9254, noting correct position Pull out with a suitable internal-arm puller e.g. 14-20, manufacturer Schrem Press in with special tool 9254, noting correct position Install only after assembly of the output shaft. Oil the sealing lip lightly and press in flush with a suitable tube As a result of overlapping tolerances, the 9 0.5 mm...

Notes on disassembly and assembly

Porsche 911 Coupling Bush

Remove snap ring No. 19 through the assembly holes in the clutch sleeve with a suitable tool. 2. Remove collar nut No. 23 with Special Tools 9275, 9276 and 9280. 3. Remove inner bearing race No. 26 with Special Tools 9278 and 9294. 4. Remove lock nut No. 29 with Special Tools 9276 and 9277. 5. Pull out inner bearing race No. 28 over the bearing carrier with Special Tool 9294 and a suitable puller. Counternut No. 29 must be unscrewed beforehand. 1. Apply a film of transmission oil to inner...

Modifications from 1991 model on Note

Case Rps Friction Plates

Before dismantling the transmission always check the amount of wear on the front-rear locking plates see Vol. IV, Page D39 45-21 . If plates are re-used after having been operated for a period, the bearing pin of the counter-bearing bolt must remain in the same position as before. If it has to be reset or if the counter-bearing bolt has to be removed for instance to rectify a leak , the correct position for re-installing must first be determined. Determining thickness of plate cluster with...

Dismantling and assembling drive pinion

Porsche 911 Pinion Wear

Dismantling and assembling drive pinion 911 Carrera 2 Manual Transmission - Gears, Shafts Assemble with the same gearwheel. Heat to ap-prox. 120 C Check for wear, assemble in correct position with the same gearwheel cogs towards driver dogs Reassemble with the same gearwheel. Heat to approx. 120 C Always replace in pairs. Install together with selector sleeve and synchroniz ing parts Spring-loaded synchronizing parts may jump out Always replace in pairs. Install together with guide sleeve and...

Dismantling and assembly notes

Following the change of the inner discs from Gylon to Valeo, stacking, adjustment and wear limit specifications of the disc pack have been modified also refer to page D 39 45-23 . 1. Determine thickness of disc pack. Pack thickness new 37.9 0.1 mm Wear limit 36.5 mm Measure entire disc pack with cup spring but without thrust ring . Measurement Special Tool height Pack thickness If the wear limit has been reached, all inner discs must be replaced and the disc pack must be packed with the outer...

Disassembling and assembling limited slip differential

Press into position with suitable piece of tubing e.g. VW 415 Make a note of thickness for refitting Determine thickness again if necessary Remove with suitable puller and P 263 Press into position with Special Tool P 264 b Make a note of thickness for refitting Determine thickness again if necessary Replace. Slide into the groove in the hexagon-head screw, pull together at front with pliers to ensure that the tab washer is firmly linked to the hexagon head screw and secure downwards via a...

Tightening torques for front axle final drive Z

Crown wheel to differential housing hex bolt with tab washer Crown wheel to differential housing Verbus-Ripp bolt without tab washer Tightening torques for front axle final drive Z 64 Printed in Germany - XVIII, 1992 Carrera 4 Table Of Contents Carrera 2 Addendum Main Menu 911 Carrera 4 Clutch, Controls 30

Dismantling and assembling input shaft Tools

993 Porsche Main Shaft

Dismantling and assembling input shaft 911 Carrera 2 Manual Transmission - Gears, Shafts Undo with Special Tools 9177 and 9105 Use Special Tools 9177 and 9105. Torque 250 Nm 183.25 ft.lb . Punch collar to lock Press off with suitable tool e.g. Kukko 17-1 over 2nd gear fixed wheel Heat to approx. 120 C and press on with suitable pipe section Press off with suitable tool e.g. Kukko 17-1 over 2nd gear fixed wheel Heat to approx. 120 C and prvjss on with suitable pipe section Mount in vice fit...

Carrera 4Differential Transaxle System

As soon as the stocks of Gylon inner discs are exhausted, the limited-slip differential must be modified to accept Valeo inner discs when repairs are required. To do so, fit all inner and outer discs, cup spring and thrust ring and adjust pack thickness to specified value of 37.9 0.1 mm refer to p. 39 - 12a to 39 -12d . Also mark the modified transmissions for identification to highlight different wear limits by stamping a large V into the transmission housing below the lock cylinder . Also...

Adjusting drive set frontaxle drive

Ring Pinion Adjustment

Adjusting drive set front-axle drive Tools 911 Carrera 4 Differential, Transaxle System Adjusting drive set front-axle drive Practical procedure when readjusting the drive set If it is necessary to adjust drive pinion and ring gear, following this sequence will ensure an efficient working procedure 1. Determine total shim thickness Stot Si plus S2 for specified preload of tapered-roiler bearing differential. 2. Determine shim thickness S3. 3. Determine bearing pressure S4. 4. Split total shim...

Adjust drive pinion rearaxle drive

Dial Gauge Extension

The setting dimension E is given on the ring gear. 2. Set adjusting ring of measuring mandrel VW 385 1 to dimension a. 1. Install complete gear set without S3 shims and tighten all hexagon nuts for tensioning plate with 23 Nm 17 ft.lb. 3. Assemble measuring mandrel with centering disk 9109, tapered-roller bearings, plunger VW 385 14 and dial-gauge extension VW 385 15. 4. Set measuring mandrel with adjuster 385 30 to adjusting dimension 60.95 mm in the example . Set dial gauge 3 mm measuring...

Adjusting ring gear rearaxle drive

Determine total shim thickness S tot. Si S2 . The ring gear must be adjusted if the transmission case, side transmission cover, tapered-roller bearing for differential, differential housing or drive set have been replaced. The drive pinion must be removed to determine the preload of tapered-roller bearing on the 1. Make sure that the outer bearing races of the tapered roller bearings are well seated in the transmission case or side transmission cover. 2. Fit one spacer ring, 2.5 mm thick, on...

Tightening torques for manual transmission G

Hexagon nut for gear and transmission cases, side transmission cover, transfer case, intermediate case, tensioning plate Mating bearing screw engaging forks interaxle lock Collar screw reverse idler gear II Mating bearing screw engaging fork rear-axle lock Hexagon head screw halfshaft flange Crown wheel to differential housing hex bolt with tab washer Crown wheel to differential housing Verbus-Ripp bolt without tab washer Tightening torques for manual transmission G 64

Adjusting the clutch pedal Note

Porsche Carrera Drawing Pages

The following items are essential requirements for smooth clutch operation and must therefore be observed whenever the pedal is adjusted - Correct bleeding of clutch hydraulics. - Tightness of hydraulic system. - Correct setting of boost spring. - Pedal travel limited by correctly set floorboard stop. - Fitting position of pedals according to standard specification. 1. Checking the pedal return return force . With the pedal in home position, pull pedal back with a force of 30 N min. using a...

Dismantling and assembling the transfer box housing from 1991 model on

Porsche 964 Differential Lock

Dismantling and assembling the transfer box housing from 1991 model on Printed in Germany - X, 1990 Seal with Loctite 222 and tighten to 40 Nm 30 ftlb torque Do not alter the setting of this pin or remove it unless renewing the plates or the front-rear differential lock. Seal with Loctite 222 and tighten to 80 Nm 59 ftlb torque Oil lightly and press in with a suitable tube e.g. VW 418 A , making sure that the position is correct Press in with special tool 9254, making sure that position is...

Final drive differential

Porsche 964 Differential Lock

- The flexible gaiter for the slave cylinder must be installed. Slacken off the measuring cylinder adjusting screw as far as possible to make it easier to install the measuring cylinder . Install the measuring cylinder special tool 9514 on the transmission and tighten the knurled nut. Adjust to a dimension of 31 mm in the lateral locking QS range with the adjusting screw on the measuring cylinder. LS Front-rear diff. lock measuring range QS Lateral differential lock measuring range 2a -...

Removing and installing release bearing

Use pointed pliers to remove, pressing down thrust plate in a press observe correct seating of snap ring check, do not wash out, just wipe with a dry cloth always insert 2 spacers 1 spacer for 911 turbo 911 Carrera 2 4 911 Turbo 911 RS with double-mass flywheel 2. Install spring washer in correct position. 2. Install spring washer in correct position.

Manual transmission controls case

Dismantling and assembling the gearbox 34 - 1 Dismantling and assembling manual transmission modifications from 1991 model on . 34 - 8a Dismantling and assembling interaxle lock with Valeo inner discs 34 - 8c Removing and installing the sealing ring for the drive shaft 34-18 Dismantling and assembling the clamp plate 34-21 Dismantling and assembling the distributor housing 34-25 Dismantling and assembling the transfer box housing from 1991 model on 34 - 28a Dismantling and assembling the...