Dismantling and assembling drive pinion

Dismantling and assembling drive pinion

22 23 24 25

22 23 24 25

Porsche 911 Pinion Wear
6 7 8 10

911 Carrera 2 Manual Transmission - Gears, Shafts

No.

Designation

Removal

Installation

1

Inner race

1

Mark for refitting

Assemble with the same gearwheel. Heat to ap-prox. 120° C

2

Thrust washer (2.8 mm)

1

3

Cylindrical roller bearing

1

Heat to approx. 120° C

4

Thrust washer (2.8 mm)

1

5

Loose gear (1st gear)

1

Always replace in pairs

6

Synchronizing ring

1

Mark for refitting

Check for wear, assemble in correct position with the same gearwheel (cogs towards driver dogs)

7

Needle cage

1

Mark for refitting

Reassemble with the same gearwheel

8

Inner race

1

Mark for refitting

Reassemble with the same gearwheel. Heat to approx. 120° C

9

Guide sleeve

1

Remove with selector sleeve

Always replace in pairs. Install together with selector sleeve and synchroniz ing parts

10

Selector sleeve (1st and 2nd gear)

1

Spring-loaded synchronizing parts may jump out

Always replace in pairs. Install together with guide sleeve and synchronizing parts

11

Driver dog (with guide nose)

3

Do not confuse with dog for 3rd to 5th and reverse gears

12

Ball

3

No.

Designation

Remove

Installation

13

Spring

3

Mark for refitting

Free length 10.7 ± 0.2 mm, wire thickness 0,9 mm. Do not confuse with springs for 3rd to 5th and reverse gears

14

Synchronizing ring

1

Mark for refitting

Check for wear, reassemble in correct position with the same gearwheel (cogs towards driver dogs)

15

Loose gear (2nd gear)

1

Always replace in pairs

16

Needle cage

1

Mark for refitting

Reassemble with the same gearwheel

17

Inner race

1

Mark for refitting

Reassemble with the same gearwheel

18

Thrust washer (1.4 mm)

1

19

Fixed gear (3rd gear)

1

Always replace in pairs. Larger collar faces thrust washer

20

Spacer

1

21

Fixed gear (4th gear)

1

Always replace in pairs. Larger collar faces four-point bearing

22

Bearing inner race

1

Mark for refitting. Press off with suitable tool (e.g. Kukko 15-17)

Do not confuse with inner race no. 24. Heat to approx. 120° C and press into position

23

Four-point bearing

1

24

Bearing inner race

1

Mark for refitting. Press off with suitable tool (e.g. Kukko 15-17)

Do not confuse with inner race no. 22. Heat to approx. 120° C and press into position

911 Carrera 2 Manual Transmission - Gears, Shafts

No

Designation

Removal

Installation

25

Cylindrical roller bearing

1

Press off with suitable tool

Heat to approx. 120° C

(e.g. Kukko 15-17)

and use a suitable pipe

section (e.g. VW 519) to

press into correct posi

tion

26

Drive pinion

1

Observe matching num

ber. Readjust if necessary

Note

Items 1 through 20 are removed without removing the drive pinion.

Notes on dismantling and assembling Dismantling

Note

To facilitate reassembly, the drive pinion remains installed for part of the dismantling steps (refer to Dismantling and assembling transmission, on page 34 - 201)

Assembling

1. Mount tensioning plate with input shaft in vice (fit protective jaws) and reassemble drive pinion.

Note

All parts of the drive pinion must be assembled dry to ensure that no oil penetrated between the mating faces. Check matching numbers on drive pinion and ring gear for reassembly. Both numbers must be identical.

2. Heat bearing inner race of four-point bearing to approx. 120° C and press into correct position.

A = Large inner race (Outside diameter 56 mm), pointing towards pinion head when installed B = Small inner race (outside diameter 53.5 mm), pointing towards 4th gear fixed gear.

911 Carrera 2 Manual Transmission - Gears, Shafts

3. When installing the synchronizer driver dogs, the guide nose must face the selector sleeve. The nose may point either to the left or the right.

519-35

4. To check the synchronizer rings, press rings onto the gear cones and use a feeler gauge to measure gap "A".

518-35

Assembly dimension (new) = 1.1 mm min. Wear limit = 0.6 to 0.7 mm

Removing and installing differential Tool

Pieces Porsche 964
536-39

No.

Designation

Special tool

Order number

Explanation

Thrust piece

9252

000.721.925.20

Removing and installing differential

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