Info

16 17 13 15 17 16

No.

Designation

Removal

Installation

1

Retainer

3

2

Magnet carrier plate

1

3

Tab washer

6

Fit replacement. Push into groove of adjacent bolts, pinch tabs with pliers (to lock plate around bolt) and bend down on a hexagon flat

4

Hex bolt

12

Threads must be dry and free of grease. Torque: 150 Nm (110 ft.lt»).

5

Ring gear

1

Threaded holes for ring gear bolts must be dry and free of grease. Note matching numbers. Readjust if necessary.

6

Pin

3

7

Taper roller bearing inner race

1

Pull of with suitable puller and P 263

Press on with P 264 b

8

Shim

X

Mark for refitting

Redetermine thickness if necessary

9

Taper roller bearing inner race

1

Pull off with suitable puller and P 263

Press on with P 264 b

10

Shim

X

Mark for refitting

Redetermine thickness if necessary

11

Spiral pin

1

Drive in observing correct position

12

Pin

1

No.

Designation

Removal

Installation

13

Small differential bevel gear

2

Apply MoS2 paste to curved surface. Always replace as a set (with large differential bevel gears)

14

Spacer

1

15

Needle roller sleeve (31 seperate needle rollers each)

2

Do not lose any needle rollers

To insert, coat with stiff grease

16

Large differential bevel gear

2

Apply MoS2 paste to curved surface. Always replace as a set (with small differential bevel gears)

17

Threaded fitting

2

18

Case

1

Notes on dismantling and assembling Note

The small differential bevel gears run on two needle roller bearing sleeves that comprise 31 separate needle rollers each.

Dismantling

1. Press out pin with centering mandrel 9289.

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9289

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539-39

2. Turn small differential bevel gears until centering mandrel faces the case cutouts and carefully take out the differential bevel gears. Be careful not to drop any needle rollers.

Reassembling

1. Install large differential bevel gears with pressed in threaded disks through the large differential case cutout and assemble with the halfshaft flanges.

2. Preassemble 31 needle rollers, centering mandrel 9289 and spacer on a small differential bevel gear and install through one of the case cutouts.

3. Assemble the other differential bevel gear with 31 needle rollers and carefully locate it on the centering mandrel. Be careful not to drop any needle rollers.

Note

540-39

To facilitate assembly, insert needle rollers coated with stiff grease.

4. Use centering mandrel to turn small differential bevel gears until the case bores line up.

540*38

5. Press in differential pin observing correct position, take off centering mandrel and lock pin according to specifications.

Dismantling and assembling drive torque-controlled limited slip differential for Carrera RS

Tools

672-39

No.

Designation

Special tool

Order number

Explanation

1

Connecting piece

Shop-made tool The connecting piece for the halfshaft flange may be made of 6x18 fiat steel.

2

Pressure piece

P 263

000.721.263.00

3

Pressure piece

P 264 b

000.721.264.20

Dismantling and assembling drive torque-controlled limited slip differential for Carrera RS

911 Carrera RS Transaxle System, Differential

No.

Designation

Removal

Installation

1

Large inner race of tapered roller bearing

1

Pull off with suitable puller and P 263

Press on with P 264 b

2

Adjusting shim

X

Mark for refitting

Redetermine thickness if necessary

3

Small inner race of tapered roller bearing

1

Pull off with suitable puller and P 263

Press on with P 264 b

4

Adjusting shim

X

Mark for refitting

Redetermine thickness if necessary

(omitted for Verbus-Ripp bolts)

6

Replace. Slide into the groove of the hex screws, pull together at front with pliers (to ensure that the tab washer is firmly locked with the hexagon head screw) and secure at bottom by bending over one of the hex flats

6

Hexagon head screws (with tab washer)

Verbus-Ripp bolt (without tab washer)

12

Threads must be dry and free of grease. Tighten with 150 Nm (111 ftlb)

Must always be replaced. Threads must be dry and grease-free. Tighten to 200 Nm (148 ftlb.)

7

Ring gear

1

Threaded holes must be dry and free of grease. Note matching numbers. Readjust if necessary.

8

Screw (M6x 10)

2

Tight, with 14 Nm (10 ftlb

9

Cover

1

10

Thrust washer

2

Fit in place with some grease

11

Cup washer

2

Install in correct position. Apply some stiff grease to the cover side to keep the cover in place

12

Outer disc

4

911 Carrera RS

No.

Designation

Qty.

Removal

Note:

Instalation

13

Inner disc (with molybde-nium coating)

4

14

Thrust ring

1

Mark for refitting

Do not confuse with thrust ring no. 20. Install in correct position

15

Shaft bevel gear

2

Replace only as a set (with bevel pinion)

16

Threaded washer

2

17

Bevel pinion

4

Replace only as a set (with shaft bevel gears)

18

Shaft

1

Mark for refitting

Do not confuse with shaft no. 19, insert in correct position

19

Shaft

1

Mark for refitting

Do not confuse with shaft no. 18, insert in correct position

20

Thrust ring

1

Mark for refitting

Do not confuse with thrust ring no. 14, insert in correct position

21

Housing

1

Notes on dismantling and assembling Dismantling

Remove pan head screws (no. 8) from case cover, remove cover and take out all internal components.

Mark all thrust rings and differential shafts for reassembly.

Assembling

1. Oil all sliding surfaces of the discs, thrust rings and differential shafts with transmission oil.

2. Install cup washers in such a way that the domed surface points towards the inside (towards the disc package).

1 - Cup spring

2 - Outer disc

3 - Inner disc

4 - Thrust washer

3. Install thrust rings and differential shafts in correct position.

665-39

A = Thrust ring (cover side) B = Thrust ring (case side)

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666-39

A = Thrust ring (cover side) B = Thrust ring (case side)

911 Carrera RS

4. Determine thickness of disc package "d" (only required if components are to be replaced).

- Determine case depth, dimension "a" Example: a = 106. 35

668-39

- Determine dimension "b" of cover. Two measurements are required to determine this dimension.

Measurement I = e. g. 20.95 mm

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669-39

670-39

- b = Measurement I - Measurement II

- Calculate clearance "c" inside casing, c = a - b

- Determine dimension "d"

(disc package with 2.0 mm outer discs and inner discs but without cup springs). Example: d = 81.50 mm

H

U,

671-39

A = Plate of Special Tool 9508/1

- Determine dimension "e" (must be 5.20 mm).

If dimension "e" is exceeded or if the dimension remains below this value, fit thicker or thinner outer discs.

"e" below 5.20 mm - install thinner discs

"e" above 5.20 mm - install thicker discs

Outer discs are available in a thickness of 1.9 mm, 2.0 mm and 2.1 mm.

5. Following assembly, measure spinning torque with one fixed shaft bevel gear and one driven shaft bevel gear. For this purpose, fit one flange with two bolts in a vise and position differential. Insert other flange with shop-made connecting piece and rotate differential with a torque wrench. A torque of 20...50 Nm (15...37 ftlb) must be attained.

A = Connecting piece (shop-made) Note

If the prescribed torque is not attained when the thickest outer discs are fitted, all discs are worn and must be replaced.

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