Dismantling and assembling transmission housing

Gearbox Porsche 968

1139-34

No.

Designation

Removal

Installation

1

Plug

2

Tighten to 35 Nm (26 ftlb)

2

Reverse light switch

1

Tighten to 20 Nm (15 ftlb)

3

Pan head screw

3

Tighten to 25 Nm (18 ftlb)

4

Cover

1

5

Sealing ring

1

Replace

6

Pan head screw

10

Tighten to 25 Nm (18 ftlb)

7

Transmission side cover

1

When replacing cover, adjust ring gear

8

Sealing ring

1

Replace

9

Shaft seal

2

Pack space between sealing lip and dust lip with multi-purpose grease. Use Special Tool 9534 to drive in to stop

10

Snap ring

1

11

Shroud

1

12

Snap ring

1

13

Form magneto

1

14

Threaded flange

1

Before screwing in, coat with Loctite 271. Tightening torque 10 Nm (7 ftlb)

15

Shaft seal

1

May also be replaced if transmission has not been dismantled.

Do not fit until gear set has been installed (refer to page 34-7). Pack space between dust lip and sealing lip with multipurpose grease

16

Needle roller bearing

1

Pull out with internal puller 30 - 37 mm (e.g. Kukko 21/5), VW 771/15 and VW 771/1

Press in to stop (e.g. with P 381). The lettering on the bearing must face the thrust piece

No.

Designation

Removal

Installation

17

Snap ring

1

18

Ball sleeve

1

Pull out with internal puller 14...20 mm (e.g. Kukko 21/2), VW 771/15 and 771/1

Replace, use Special Tool 9223 to drive in to stop

19

Shaft seal

1

Pull out with VW 681. May also be replaced if transmission has not been dismantled

Pack space between dust lip and sealing lip with multipurpose grease. Drive in to stop using Special Tool 9223

20

Cover plate

1

Press retaining lug down, inserting a small screwdriver through the breather tube, and pull out

Engage retaining lug into breather tube

21

Ball sleeve

2

Pull out with internal puller 14...20 mm (e.g. Kukko 21/2), VW 771/1 and VW 771/15

Replace, drive in with Special Tool 9223

22

Snap ring

1

Lever out with two screwdrivers

Check for correct seating

23

Needle roller bearing

1

Pull out with internal puller 30...37 mm (e.g. Kukko 21/5), VW 771/1 and VW 771/15

Press into correct pos. (e.g. with VW 454). Make sure the lettering on the bearing faces the thrust piece „a" = 105 mm

24

Tapered roller bearing outer race

1

Pull out with internal puller 71 ...100 mm (e.g. Kukko 21/9) and countersupport

Press in to stop (e.g. with Special Tool 9247/4), supporting cover at the aperture for the joint flange. When replacing, readjust ring gear.

25

Tapered roller bearing outer race

1

Pull out with internal puller 50...70 mm (e.g. Kukko 21/8) and countersupport

Press in to stop (e.g. with Special Tool 2050). The large diameter must face the outer race. When replacing, readjust ring gear.

No.

Designation

Removal

Installation

26

Tapered roller bearing outer race

1

Drive out using Special Tool 9247/4 and VW 771/1

Heat transmission housing to approx. 120*C and press in with Special Tool 9247/3 and P 254, using a shop press. Continue pressing for 1 to 2 minutes until heat exchange has occurred

27

Adjusting shim „S3"

X

Note thickness for reinstallation

If required, recalculate thickness

(refer to page 39-17)

28

Cap

1

Pull off manually

29

Bleeder tube

1

Observe correct pressing depth, „a" = 18 ± 0.5 mm

30

Transmission housing

1

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