Adjusting circumferential backlash Note

The backlash to be set is embossed on the ring gear. 1. Mount gear set using the shims S3 determined while adjusting the drive pinion and tighten all mounting screws to 50 Nm Make sure the collar nut of the drive pinion is tightened to 250 Nm (184 ftlb). 2. Fit the adjusting shims (Si + S2) determined into the transmission case and the transmission side cover, respectively. 3. Fit differential and transmission side cover and tighten all hexagon head bolts of the cover to 23 Nm (17 ftlb). Always...

Adjusting drive pinion Note

The setting dimension E is indicated on the ring gear. 1. Install drive pinion without shims S3 and tighten all pan head screws of bearing assembly to 50 Nm (37 ftlb). 2. Rotate adjustable stop ring along with spindle towards measuring plunger as far as it will go and set second setting ring to dimensiona. 3. Assemble measuring mandrel and set with master gauge VW 385 30 to setting dimension E (64.05 mm in the example). Set dial gauge (3 mm measuring range) to zero with 1 mm preload. 4. Put...

Adjusting drive set General

The setting of drive pinion and ring gear is a determining factor for the service life and smooth running of the rear-axle drive. Drive pinions and ring 'gear that have been checked for good tooth contact pattern and low noise in both directions of rotation on special test equipment are therefore matched during production. The position at which smoothest running can be achieved is determined by shifting the drive pinion axially, with the ring gear being kept within the tolerance of the...

Adjusting ring gear

Determining total shim thickness Stot. (Si + S2) The ring gear must be readjusted if the transmission case, transmission side cover, taper roller bearing for differential, differential housing or drive set have been replaced. The drive pinion must be removed in order to determine the preload of the differential tapered roller bearings. 1. Remove adjusting shim Si (in transmission side cover). 2. Adjusting shim S2 remains in the transmission case. 3. Make sure that the bearing outer races of the...

Determining installation position of drive pinion Measuring actual values

Initial production vehicles used drive sets that did not have the E and F marks for service adjustment. When replacing components that affect the drive pinion position directly on those transmissions, the actual values must be measured. 2. Assemble measuring mandrel VW 385 1 and set to design dimension Ro 64.00 mm. (Refer to page 39 - 129). 3. Install measuring mandrel and measure difference (deviation r) to Ro. 4. Design dimension Ro plus deviation r equals the actual or setting dimension E....

Determining the end clearance

Sleeve Bearing Clearance Chart

Check the end clearance whenever the transmission has been reassembled and readjust if required, using adjusting washer No. 12 (refer to page 37 - 105). 1. Assembly transmission (complete with spur gear drive and front transmission cover). 2. Screw centering pins 9321 into transmission case and apply some grease (vaseline) to stick paper gasket to sealing surface. 3. Using some grease (use vaseline), stick the removed adjusting washer to the rear transmission case and put housing carefully into...

Dismantling and assembling brake C C and D

Remove with Special Tool 9332 and a bar magnet, Install with Special Tool 9332, using a press Center in such a way that it is not squeezed by the retainer ring To remove, apply compressed air across the oil feed bore Do not confuse with piston C. Grease seals with vaseline and push them carefully onto the centering plate, making sure the piston does not bind Fit into correct position Wider section of teeth faces inside Ring ends must be hooked into each other If required, reestablish correct...

Dismantling and assembling brake F

911 Carrera 2 Automatic Transmission, Gears, Controls i Do not confuse with end disc of clutch E Do not confuse with outer disc of clutch E Remove with Special Tool 9335 and a press Install with Special Tool 9335 and a press, observing correct position. Stepped side faces inside. Press out of cylinder from outside, using a suitable tool Grease round seals (with vaseline) and press carefully into cylinder, making sure the piston does not bind. To avoid damage, expand ring slightly and fit at...

Dismantling and assembling brake pack CD with spider shaft

Remove with centering plate and support ring. For dismantling, refer to page 38-152 Refer to Dismantling and assembling brake D (refer to page 38 - 152) Hook ends of rectangular rings into each other Spider shaft (with hollow gear and intermediate shaft) For dismantling, refer to page 38-147

Dismantling and assembling clutch E

911 Carrera 2 Automatic Transmission, Gears, Controls i Do not confuse with end disc of brake F Do not confuse with outer discs of brake F Remove with Special Tool 9335, using a press Install with Special Tool 9335, using a press Place into position with convex side facing down To remove, apply compressed air across oil feed bore Grease round seals (with Vaseline) and press piston carefully in place, making sure it does not bind

Dismantling and assembling drive pinion

Ring And Pinion 944

Undo with Special Tool 9337 and 9282 Tighten to 250 Nm (184 ftlb) and secure by upsetting the flange in two places Heat to approx. 120 C and press on Only available pread-justed as a complete spare assembly (items 2 to 5) Heat to approx. 120 C and press on Readjust if required, observe matching number

Dismantling and assembly notes

Special Tools Porsche

Remove and install rear transmission case (page 37 - 103). 2. Remove and install intermediate plate (page 37 - 107). 3. Remove and install parking lock (page 37-111). 5. Unscrew 13 mounting screws (head dia. 12 mm) for hydraulic control unit and lift off control unit. 6. Pull sealing sleeves out of the bores, using Special Tool 9327. 1. Using a suitable mandrel, press sealing sleeves into the bores of the transmission case. Make sure the sleeves are not tilted or damaged. A - short sealing...

Dismantling and assembly notes Dismantling

Remove retainer ring with Special Tool 9332 and a bar magnet, using a press. A - Special Tool 9332 B - Split retainer ring 2. Remove pistons C and D by applying compressed air across the oil feed bores. 3. Remove snap ring with Special Tool 9332 and suitable pliers, using a press. 3. Remove retainer ring with Special Tool 9332 and a bar magnet, using a press. A - Special Tool 9332 B - Split retainer ring 4. Remove piston C' by applying compressed air across the poil feed bore. 1. Install snap...

Instructions for removal and installation

Remove underfioor paneling for gearbox and center underfioor paneling. 2. Disconnect cable on operating lever and remove fork head. 4. Disconnect cable on selector lever casing and disconnect guide tube. 1. Installation is carried out in reverse order. 2. Adjust cable for selector mechanism (see P. 37 - 102a). 911 Carrera 2 Automatic Transmission - Operation, Housing

Practical procedure when readjusting the drive set

If it becomes necessary to adjust drive pinion and ring gear, follow the below sequence to ensure an efficient working procedure 1. Determine the total shim thickness Stot (Si plus S2) for the specified preload on the taper roller bearings differential. 2. Determine the thickness of shim S3. 3. Split the total shim thickness Stot into Si and S2 so that the specified circumferential backlash is present between ring gear and drive pinion. The aim of this adjustment is to restore the smoothest...

Removing

The transmission wiring harness remains on the transmission. 1. Remove the transmission underbody cladding. 3. Remove ATF pan. To do this, unscrew hollow screw for oil level pipe and six fixing screws. 4. Remove ATF strainer with Torx insert T 27. 6. Unscrew 13 fixing screws (head diameter 12 mm) with Torx insert T 27 and lower control unit only so far as to guarantee that the wiring harness is not subjected to any tension. Place the control unit on a suitable surface (e.g. transmission jack)....

Removing and installing keylock bowden cable Removal

Porsche 911 Valve Adjustment

Undo mounting screws of valve body. 2. Remove complete center console, knee guard and side nozzle. 3. Undo Central Information System and leave it supended on the wiring. 4. Turn ignition lock to position 2 (Ignition on). Note The ignition lock must be in position 2. If it is left in any other position, both the lock and the bowden cable may be damaged. 5. Unbolt bowden cable from ignition lock. 5. Unbolt bowden cable from ignition lock. 7. Disengage bowden cable from...

Removing and installing solenoid valves

Set by the manufacturer, only replace complete Fit in correct position, lugs point to holder No. 5 Do not confuse with solenoid valves Nos. 11 and 14 Fit in correct position, lugs point to housing Do not confuse with solenoid valves Nos. 14 and 8 Fit in correct position, lugs point to housing Do not confuse with solenoid valves Nos. 11 and 8

Removing and installing the ATF pump

Remove torque converter and rear transmission case. 3. Unscrew fixing screws with Torx insert T27 and remove pump. To do this, screw in two screws opposite each other and carefully drive out the pump by gentle blows on the screw heads 1. Check bearing bush for run-in scores or damage. The pump must be replaced If there are signs of damage. 2. Oil both pump wheels with ATF fluid and place in the housing so that both installation markings are visibly facing up. 3. Install pump with new O-ring and...

Removing and installing the rotary shaft seal for the short joint flange

The rotary shaft seal can also be replaced with the transmission in built-in condition. 1. Unscrew the hexagon screw for the joint flange and remove flange. 2. Lever out rotary shaft seal with VW 681. Installing 1. Press in rotary shaft seal flush with suitable pressure piece. 2. Tighten hexagon screw for joint flange with 46 Nm (34 ftlb). Removing and installing the rotary shaft seal for the short joint flange

Sealing off the driving shaft

Remove engine with gearbox (do not unbolt engine from gearbox. 3. Remove intermediate plate (see page 37 - 107). 4. Remove bearing cap with Torx insert T 27 and replace rotary shaft seal. Pack space between dust lip and sealing lip with grease (e.g. Shell 8420). 5. Fit bearing cap with new O-ring and tighten fixing screws with 10 Nm. 6. Remove snap ring for bearing cap at intermediate plate and pull out cap. Pack space between dust lip and sealing lip with grease (e.g. Shell 8420). Press-in...

T

Dismantling and assembling transmission 911 Carrera 2 Automatic Transmission - Operation, Housing < Check shim thickness whenever the transmission has been dismantled and redetermine correct thickness as required (refer to page 38-171) For dismantling and assembly, refer to page 38-168 Use grease (vaseline) to stick to drive shaft in correct position Pull out using Special Tool 9328 1. For dismantling and assembly, refer to page 38-161 Check rectangular ring for correct position Lift out with...

Dismantling and assembling transmission

911 Carrera 2 Automatic Transmission - Operation, Housing v Short legs must force on the ATF pan Short legs must force on the ATF pan Observe correct length, tighten to 8 Nm (6 ftlb) Hydraulic control unit with wiring harness The straight surface on the harness socket must point towards the outside Observe correct length, tighten to 8 Nm (6 ftlb) Press in to stop using a suitable mandrel Press in to stop, observing correct position 911 Carrera 2 Automatic Transmission - Operation, Housing

Dismantling and assembling 4th gear tower

911 Carrera 2 Automatic Transmission, Gears, Controls i Check for correct seating of the rectangular ring. Engage into hollow gear with a slight rotary motion For dismantling, refer to page 38 - 137 Make sure rectangular rings are located correctly. Rotate them slightly to move them into installation position For dismantling, refer to page 38-131 Fit with a rotary motion. The specified position is achieved when cylinder E rests against the copper angle disc For dismantling, refer to page 38-127...

Major Data at a Glance

Automatic four-speed sports transmission with integral hypoid final drive, with manual and automatic shift features. No. of gears 4 forward gears, 1 reverse Porsche model designation A 50.01 A 50.02 A 50.03 Spur gear drive 30 33 i 1.100 Final drive i 3.667 3.667 3.556 Control unit 8-bit microprocessor with external 32 KB EPROM memory Transmission unit overall weight 98 kg Extra weight 911 Carrera 2 vehicle with Tiptronic 34 kg Automatic section Initial filling approx. 9.1 I, ATF Dexron II D...

Removing and installing differential and drive pinion

Fresh Air Flap Vehicle

For dismantling, refer to page 39 -102 Pack space between dust lip and sealing lip with grease e.g. Shell 8420 and press in flush Replace. Pack space between dust lip and sealing lip with grease e.g. Shell 8420 . Press in to depth of 2.0 0.5 mm To drive out, use a plastic hammer to apply light blows on the drive pinion head Observe matching number, readjust if required

Removing and installing gear selecting system

Porsche 911 Tightening Torques

Disengage selector lever cable from deflection lever and undo guide tube. 4. Unscrew release button and pull off selector knob. 6. Disconnect cable valve body from switch plate only for keylock models . 7. Disconnect connectors for switch plate. 8. Unscrew four mounting screws M 6 and take out selector lever operator from above. Gear selecting system to body 10 Nm 7 ftlb 2. Press selector knob manually until it is up against the stop, making sure the twist...

Workshop Manual

964 Tiptronic Differential

Porsche Aktiengesellschaft The workshop manual is only for the internal use of the Porsche Dealer Organization. 1988 Dr. Ing. h.c. F. Porsche Aktiengesellschaft Technical Service Department D-7140 Ludwigsburg All rights reserved - Printed in Germany Engine, Cylinder Head and Valve Drive Starter, Power Supply, Cruise Control Differential, Transaxle System, All-Wheel Drive Automatic Transmission, Controls, Case Automatic Transmission, Gears, Shafts Brakes, Hydraulics, Regulator,...

Adjusting the preload of the spur gear taper roller bearings

Adjusting spur gear II intermediate gear 1. Determine and record dimension a e.g. 45.90 mm . 2. Fit complete spur gear II and determine dimension b e.g. 44.65 mm . Record measured value. 3. Determine shim thickness by deducting dimension b from dimension a and adding a constant value of 0.22 mm preload and thickness of compressed gasket . The constant value is 0.22 mm for all transmissions. Dimension a e.g. Dimension b e.g. Always round shim thickness up or down to the nearest 0.05 mm figure....

This is how the information is processed in the Tiptronic control unit

Porsche Transverse Acceleration Sensor

Adaption of shift characteristics transmission and torque converter shift characteristics TC characteristics r computer controlled maintenance of recommended max. engine speeds The Tiptronic control unit is located below the left-hand seat and is built into a housing that is slightly smaller than the DME control unit located in the same place. The following parameters are constantly supplied to the Tiptronic control unit Time for change of resistance at potentiometer No. of pulses at pole wheel...

Dismantling and assembling clutch B

911 Carrera 2 Automatic Transmission, Gears, Controls i Remove with Special Tool 9332 using a press Install with Special Tool 9330 1 using a press, checking for correct seating To loosen, apply compressed air across the oil feed bore and take out by knocking lightly on a wooden support Grease round seals use vaseline and press carefully into cylinder F, making sure the piston does not bind

Dismantling and assembling clutch A

Separate from cylinder by tapping lightly on a wooden support Remove with a suitable thrust piece e.g. plate of 9329 , using a press Install with a suitable thrust piece e.g. plate of 9329 , using a press Refit old discs or use new disc of the same To remove, apply compressed air across oil feed bore Grease sealing rings use vaseline and press carefully into cylinder, making sure the piston does not bind.

Dismantling and assembling differential

Differential 964 Carrera4

Threads must be dry and free from grease. Secure with Loctite 262, tighten to 85 Nm 63 ftlb Replace. Threads must be dry and free from grease. Install in correct position Separate from housing by applying light blows with a plastic hammer Observe matching number. Readjust if required Pull of with suitable puller, or remove ring gear and take out from inside through bores Heat to approx. 120 C and press on Heat to approx. 120 C and press on Dismantling and assembling differential...

Test point

transmission The sensor transmits the transmission speed. ECU compares it to the wheel speed. Tlptronic warning lamp comes on, transmission is in emergency mode. Possible faults Open circuit, short to ground, short to positive, loose connection Check with Tester 9288 actual values . Store fault as of engine speed 2800 rpm a Measure resistance between pin 2 and pin 38. Nominal value approx. 350 Ohms b Check that pin 2 und pin 38 are free from shorts to ground. - Check o.k. ECU faulty 2 Also...

Diagnosable Tiptronic control unit

A self-diagnosis feature with fault memory is built into the Tiptronic control unit to allow certain faults within the electronic control system of the Tiptronic to be detected and to be stored. To prevent detected and stored faults from being erased when the ingition is switched off, a permanent positive voltage is present at the control unit. Detected faults remain stored in the fault memory for at least 50 starts of the engine. Caution If the connector is pulled off the Tiptronic control...

Faults that cannot be detected by selfdiagnosis

The ECU cannot detect and store all potential faults. If a fault is found and if no fault has been stored, the tester may be used to run a system check to indicate any faults that may be present. Some of these faults are stated below. No diagnosis possible, Test point 0 No diagnosis is possible if the diagnostic leads are faulty. If terminal 15 is inoperative, the system enters the mechanical-hydraulic emergency mode. The fault lamp does not come on. If terminal 30 is inoperative, all faults...

Removing and installing lift solenoid for shiftlock

When checking the lift solenoid electrically, be sure to observe correct polarity Terminal 1 Positive Terminal 2 Negative 1. Remove center console and gear selecting system. 3. Using a suitable tool, press connecting rod carefully off the lift solenoid. 4. Screw out mounting screws and take off lift solenoid. 1. Set selector lever to 1 position. 2. Grease ball and ball socket with low-temperature grease. 3. Clip connecting rod to lift solenoid, retaining the connecting rod in correct position...

Dismantling and assembling output shaft and freewheel

Remove with suitable pliers and screwdriver Install with suitable pliers e.g. VW 161a Rotate to lift off along with freewheel cage Rotate clockwise to push onto Inner ring along with freewheel Mark installation position for reassembly. Press carefully out of outer ring Use Special Tool 9336 to place into outer ring

Dismantling and assembling selector mechanism

Porsche 964 Gearbox Bracket

Must return automatically to original position after operation Press on in correct position until properly in contact. Twisting lock must engage with lock on shift lever. Can only be taken out from below and with center console removed Must engage in recess in control plate Coat all sliding surfaces in low-temperature grease e.g. Shell S 6508 911 Carrera 2 Automatic Transmission, Operation, Housing Dismantling and assembling gear selecting system with keylock and shiftlock Tools Dismantling and...

Changing ATF fluid and cleaning the

Capacity approx. 9.5 I Change quantity approx. 3.5 I The ATF fluid must be changed and the ATF strainer cleaned every 40,000 km When changing the ATF fluid, the vehicle must be horizontal and the engine switched off. Drain ATF fluid, remove ATF pan and ATF strainer refer to page 38-109 . Thoroughly clean the strainer and pan. Fit the ATF strainer with a new O-ring. Tighten the fixing screws with 8 Nm 6 ftlb . Fit the ATF pan with seal. Tighten the fixing screws with 8 Nm 6 ftlb .

Technical data

Porsche 964 Oil Flow Diagram

Fully-automatic 4-speed planetary transmission Tiptronic Capacity, rear axle final drive approx. 0.9 I multi-grade transmission oil 75 W 90 API classification GL5 MIL-L 2105 B , optionally SAE 90 Capacity, automatic unit Total capacity approx. 9.5 I with converter Change quantity approx. 3.5 I ATF-Dexron II D Removing and installing the torque converter Removing 2. Secure converter against falling out with 1. Remove transmission. sPecial to ' 9325 2. Remove converter, with transmission in...

Removing and installing the intermediate plate

Porsche 964 Car Audio

911 Carrera 2 Automatic transmission, controls, case Gear wheel with tapered-roller bearings Note correct position for reinstallation Note correct position for reinstallation Remove with internal puller e.g. Schrem 60 - 70 Heat transmission cover to approx 120 deg. C and press in to stop Automatic transmission with final drive The spur gear drive is only available as a complete set intermediate plate, transmission cover and adjusted spur gears . No adjustment of the preload of the taper roller...

Dismantling and assembling gear selecting system with keylock and shiftlock

37 - 102n Dismantling and assembling gear selecting system with keylock and shiftlock 911 Carrera 2 Automatic Transmission - Operation, Housing Must return to home position automatically after it has been actuated Push up to stop in correct position. Twist lock must engage in cutout in selector lever Can only be removed from below with the center Bore of driver and relay shaft must match Shift into manual speed selection gate Coat all sliding surfaces with low-temperature grease e.g. Shell S...