Removing and installing input shaft

Tools

35 40 19 Removing and installing input shaft

Input Shaft Bearing Removal Tool

No.

Designation

Removal

Installation

1

Cylindrical roller bearing

1

Heat to appro*. 120 "C

2

Shift rod (51h and 6th gear)

1

Ijhift rods in neutral position

3

Spacer

1

Coat with stiff grease to Insert

4

inner race

1

Fit with the same gearwheel. Heat to appro*. 120 C

5

Thrust washer

1

6

Cylindrical roller bearing

1

Heat to approx. 120 *C

7

Thrust washer

1

S

Loose gearwheel (1 si gear)

1

9

Friction ring*

1

Fit with the same gearwheel

10

Tapered ring

1

Fit with the same gearwheel. Tabs must engage into the cutouts in the loose gearwheel

11

Synchronising ring"

'

Check for wear. Fit with the same gearwheel. Drivers must engage In Ihe cutouts in the tape-red ring. Thre^ lugs face the driver dogs.

12

Needle roller bearing

1

Fit wilh the same gearwheel

13

Inner race

1

Fit with the same gearwheel. Heat to approx. 120 "C

Porsche 993 Restoration

No.

Designation

Removal

Installation

23

Tapered ring

1

Fit with the same gearwheel. Tabs mus? engage into the cutouts in the loo se gearwheel

24

Friction ring

1

Fit with the same gearwheel

£5

Loose gearwheel (End gear)

1

26

Needle roller bearing

1

Fit with the same gearwheel

27

Inner race

t

Fit with tne same gearwheel, Heat to acprox. 120 "C

28

Thrust washer

1

29

Fixed gearwheel (3rd gear)

1

Large collar faces thrust washer No. 35

30

Spacer sleeve

1

31

Straight pin

4

32

Washer

4

Gmcle lug faces spring

33

Thrust spring

4

34

Latch

4

35

Fixed gearwheel (4th gear)

1

Large collar faces Four-po Inl bearing

36

Output shaft

1

37

Flange nut"

1

Undo with Special Tools 9282 and 9105

Tighten to 250 Nm (1S4 ft lb.). Upset the flan ge to lock

33

Cylindrical roller bearing

1

Press oft across 2nd gear fixed gearwheel

Heat lo approx, 120 UC

39

Beanng inner race

1

Heat to approx. 120 DC

35 40 19 Removing and installing input shaft

Printed in Germanv - 20. 1997

Designation

Qty.

Removal

Note:

Installation

40

Four-point bearing

1

41

Output shaft

1

Insert complete with pinned shift rod / shift fork (No. 42)

42

Shift rod with pinned shift fork

1

43

Lock (short)

1

44

Lock (long)

1

45

Lock (short)

1

46

Tensioning plate

1

** Transmission shafts without recesses for securing the hexagon nuts have been installed since Spetember 1995.

Self-locking hexagon nuts are used on these shafts, and these nuts must always be replaced in every transmission repair.

Removal and installing notes

Removal 3. Observe installation position of locks

Note

Parts No. 1 to 30 are removed with the tensioning plate remaining fitted (refer to page 34 -11).

Installation

Using a suitable flat iron bar, clamp tensioning plate in a vise in such a manner that the hole for the shift rod locks is horizontal.

2. Check synchromesh of 1st and 2nd gears. To do so, place friction ring, tapered ring and synchronizing ring in correct position onto gearwheel. Check gap "A" with a feeler gauge. Old design:

installation dimension (new) = 1.3 to 1.95 mm wear dimension = 1.0 mm New design:

installation dimension (new) = 1.5 to 2.0 mm wear dimension = 1.2 mm (see page 35-14)

1709-35

1 = Shift rod 3rd and 4th gear

3 = Shift rod 5th and 6th gear

4 = Intermediate lock

6 = Reverse shift rod

7 = Intermediate lock

9 = Shift rod 1st and 2nd gear

Note

After fitting the shift rods, do not move them across the neutral or gear latch positions as this may cause the small intermediate locks to drop out inadvertently. To avoid inadvertent movement of the shift rods, lock shift rods by engaging 4th gear.

1701-35

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