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Porsche 911 TURBO - 1989, Manual

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Porsche 911 TURBO - 1989 Manual Download Page 44

Summary of Contents for 911 TURBO - 1989

Page 1: ...speed with rear axle final drive 9 38 standard 930 32 4 speed with rear axle final drive 9 36 not for USA The following transmissionis installed from 1977Models 930 33 4 speed with a final drive ratio...

Page 2: ...arbox corresponds to the G 50 00 Carrera gearbox with regards to construction and repair The gearbox has been reinforced however and the transmission ratios modified to suit the high engine performanc...

Page 3: ...r No 18 8 22 25 2 2 2 5 Backup light switch Gear housing M 18xl 5 MS 25 35 2 5 3 5 Gearshift forks M 6xl O 8 8 9 11 0 9 1 1 Hex nut M 8xl 25 8 22 25 2 2 2 5 Clamp gears transm I case front and side co...

Page 4: ...O 8 8 20 5 2 0 2 5 Starter Hex nut M lOxl 5 8 46 50 4 6 5 0 Mech controls Holderto base Hex hd screw M6 8 8 6 0 6 Baseto tunnel Socket head capscrew M8 8 8 21 2 1 I Con screw in shift rod end Con scre...

Page 5: ...Finaldrive Final drive ratio 9 38 i 4 222 optional 9 36 9 38 i 4 222 9 38 i 4 222 4 1976 models 1977 models 1978 models to 1981 models Via double joint shafts to rear wheels Powertransmission 53 kg T...

Page 6: ...General Data TechnicalData Printed in Germany III 1978 30 07...

Page 7: ...1 III 1978 Printed in Germany Removing and Installing Clutch Disc 30 1...

Page 8: ...30 Clutch Control Removing andInstalling Clutch Disc Printed in Germany 30 2...

Page 9: ...crewevenly Tightenevenlyand diagonally torque 2 0 2 5 mkg 14 18 5 ft Ibs 2 Washer 6 Replace if needed 3 Ring gear 1 Check for wear 4 Pressureplate 1 5 Throwout bearing 1 Don t wash Wipe with dry rag C...

Page 10: ...istortion on clutch pressureplate 5 Checkdisc with lining for lateral runout Permissible lateral runout on225 mm diameterismax 0 6 mm CHECKING CLUTCH DISC 1 Checkteeth The clutch disc mustmove easilyi...

Page 11: ...embly thoroughlywith compressed air 2 Check endsof diaphragm springs for traces of wear from clutch release bearing Wear up to a depth of 0 3 mm is not serious 4 Checkspringconnections between pressur...

Page 12: ...aringin flywheel with about1 cm3 1 5 grams of MoS2 grease 3 Install clutch with specialtool 9102to centerin flywheel 4 Centerclutch pressure plate onflywheel 5 Tighten bolts evenly and diagonally to p...

Page 13: ...clutch servo it is no longer possible to check the clutch play exactly at the clutch pedal This is why the clutch play of cars with a servo clutch has to be checked at the transmissionadjusting lever...

Page 14: ...DISASSEMBLING AND ASSEMBLING CLUTCH Disassembling andAssemblingClutch III 1978 Printed in Germany 30 8...

Page 15: ...NG AND ASSEMBLING CLUTCH 1 Three clips can be usedto facilitate installa tion of clutch pressureplate These clips are mounted on all spare part clutch pressureplates and must be removed after installa...

Page 16: ...d bearing surfaces with a waterproof lubricant for example Staburags NBU 12 300 KB from Kli iber or a multi purpose grease Release lever bore Release lever shaft also splines for adjusting lever Relea...

Page 17: ...til releasespring passesthe top dead center point lever snaps against stop on console 3 Remove adjusting lever again and mount asclose as possible to releaselever 4 Make basic clutch adjustment Removi...

Page 18: ...cars with power clutch will have to be checked at transmissionadjusting lever 2 Adjustclutch play to 1 2 0 1 mm with a feelergaugeand counterlockadjustingbolt 1 Check whetherclutchcableis tight 2 If...

Page 19: ...isengage clutch and measuredistance II as shownin figure e g 74 7 mm Note If adjusting room on clutch cable holder is not sufficient also adjust front end at pedals For this purpose adjust stop on flo...

Page 20: ...911 turbo Clutch Control Clutch mechanism disassembling and assembling from Model 89 onward C f 1 2 155 30 30 15...

Page 21: ...out with hexagon he ad bolt M6x40 1 6 Sealing ring 2 Check replace if neces sary install in correct po sition 7 Clutch release lever 1 8 1 9 Needle bearing without as sembly hole Plastic bushing 1 Ins...

Page 22: ...gear shift system actuat hous Printed in Germ ny Dismantling and Assembling Front TransmissionCover 34 1...

Page 23: ...Driveout Heatcoverto 0 ca 120 C and drive in 3 Operating lever spacer 1 Drive out Heatco erto ca 120 C and drive in I 4 Fronthousing cover 1 DISMANTLING AND ASSEMBLING INSTRUCTIONS Dismantling 1 Pryou...

Page 24: ...gear shift system actuat house TOOLS 3 2 Designation Special Tool Remarks No Mandrel Partof P 254 1 Pressurepad P 254 b 2 Pressurepad P 254 c 3 DismantlingandAssembling GearHousing 34 3 Printed in Ger...

Page 25: ...Manual Transmission Controls Case Printed in Germany 34 4 Dismantling and Assembling Gear Housing...

Page 26: ...e 8 Pin 1 9 Reverse operating lever 1 10 ReveIse rod 1 Removing with small screw driver 11 Snapring 2 Install correctly 12 Outer race with snapring Drive out with P254b 1 Heatgearhsg to 0 ca 120 C and...

Page 27: ...54 b or254c The bearing outer races have different inside diameters The bearing outer race with the largest inside diameter belongs to the driven shaft cylindrical roller bearing Assembling 1 Heat gea...

Page 28: ...ctuat hoDs TOOLS No Designation Special Tool Remarks Pressurepad P 254 d 1 LocalManufac 2 Hook Mandrel P 375 3 Pressurepad P 254 a 4 P 265 c 5 Pressure pad Printed in Germany Dismantling and Assemblin...

Page 29: ...gear shift system actuat house Printed in Germany 34 8 Dismantling and Assembling TransmissionCase...

Page 30: ...7 Seal 1 8 Key 1 Lever shaft 9 1 Coat with a MaS lubricant 2 10 Release fork 1 Adjust Guard 11 1 12 Bushing long 1 Drive out with P375 Drive in with P 375 correctly Bushing 13 1 Drive out with P375 D...

Page 31: ...1 Torqueto specifications 28 Shaft seal 1 Drive in with P 265 c 29 1 Outer race Heat transm case 0 to ca 120 C and drive in 30 Outer race 1 Drive out with P254d Heatcaseto ca 120 Canddrive in with P25...

Page 32: ...ed hook Assembling 2 Drive out spiralpin forreleasefork 1 Clean transmissioncase and check for wear exterior damage and cracks If drive pinions or ring gears are damaged e g broken check if the bearin...

Page 33: ...ace forwardtowardtransmission cover 5 Drive in lever shaft bushings with P 375 4 Install selectorrodlocks 1 Bearing sleeve Delrin 2 Lever shaft bushing short 3 Transmission Case 4 Guard 5 Lever shaft...

Page 34: ...6 Adjustreleaseforksandreleaselevers The distances are76 5 mm and93 mm 7 Drive in stubaxle sealwith P265c Note Insert the drive shaft seal guide tube after installation of the drive shaft...

Page 35: ...mission Controls Case TRANSMISSIOf CASE WITH CLUTCH BOOSTER 19 r 23 16 18 r 22 i 21 j 17 20 J 20 14 13 15 6 7 8 5 9 4 3 10 2 1 12 11 II 1976 Printed in Germany Disassembling and Assembling Transmissio...

Page 36: ...place if necessary 8 Washer 1 9 Spring 1 10 Washer 1 Adjusting screw 11 1 12 Tighten to specified torque Hexagon nut 1 Tighten to specified torque 13 Hexagon nut 4 Replace if necessary 14 Washer 4 15...

Page 37: ...2 Drive out with P 375 Drive in with P 375 until positioned correct ly 21 Protectivepipe 1 22 Bushing 1 Drive out with P 375 Drive in with P 375 until positioned correctly 23 Bushing 1 Replace drive...

Page 38: ...propriate tool Only mount the adjusting lever after the engine transmission assemblyhas been installed in car Adjust clutch see Repair Manual 911 Main Group 7 Page2 1 2 3 Note The spring will snapback...

Page 39: ...mission Controls Case T ANSMISSION CASE WITH POWER CLUTCH FROM 1978 MODELS 19 16 15 12 17 18 18 13 14 14 7 11 10 9 6 8 5 3 4 7 2 1 Disassembling andAssembling Transmission Case 34 14 e Printed in Germ...

Page 40: ...Spring 1 7 Seal 2 Replace 8 Releaselever 1 9 Hexagon nut 1 10 Spring washer 1 11 Base 1 12 Key 1 13 Lever shaft 1 14 a ring 2 Replace Release fork 15 1 16 Seal 1 Replace 17 Seal 1 Replace 18 Bushing 2...

Page 41: ...1 2 Drive outbearingbushings with9167andman drel fromP254 Assembling 1 Drive in bushings for lever shaft with 9167 and mandrel from P 254 see drawing and coat with a greasehaving a lithium or silico n...

Page 42: ...TOOLS No Designations Special Tool Remarks Local manufacture 1 Installinglever 2 Pressurepad P 299 Printed in Germany Dismantling and Assembling Gearshift Base 34 15...

Page 43: ...Manual Transmission Controls Case Printed in Germany 34 16 Dismantling and Assembling Gearshift Base...

Page 44: ...1 8 9 Hex nut M 6 2 Replace if necessary 10 Lockwasher 2 Holder 1 11 3rd and 4th gear opening faces right in driving direction Coat inside with MoS libricant 12 Padplate 1 Ball socket 1 Apply MoS2 lub...

Page 45: ...D ASS EMBLING INSTRUCTIONS Assembling Dismantling 1 Clamp geanhift base in a vise Move selector lever in shifting direction Pressuremustbuild up from min 250 g to max 600g Bendspring in gearshift bas...

Page 46: ...Move selector lever in idle position so that the lower part of the selector lever is vertical and on rigth stop 3rd and 4th gear 3 Tighten selectorrod clampslightly 4 Check if shift travel is just as...

Page 47: ...TOOLS Remarks Description Special Tool No No 9106 1 Holder Disassembling andAssembling Gears Shafts Printed in Germany It 1976 35 1...

Page 48: ...Manual Transmission Gears Shafts Disassembling and Assembling Gears Shafts 35 2 Printed in Germany...

Page 49: ...1 Replace Block trans mission with 2 gears and loosen 10 Nut 1 Replace Torqueto specifications Pry off with 2 screwdrivers 11 Rev gearIII 1 Replace if necessary Torqueto specifications Self locking h...

Page 50: ...h 1 Torque to specifications 20 Pin 1 Installcorrectly Long end faces in 21 Hex nut 10 Torque to specifications Washer 22 10 23 Gearhousing 1 Move selector rods to off position and remove 24 Gasket 1...

Page 51: ...d place in 4th 4 Remove all parts from drive pinion and drive shaft and mark needle bearings for installation also refer to Dismantling and Assembling Drive Pinion and Drive Shaft 2 Unscrew reversegea...

Page 52: ...r II b Needle cage spacer 4th speedgear I c Operating sleeve for 3rd and 4th speed d Gearshift sleeve selector fork and selector rod for 3rd and 4th speed e Bushing spacer needle cage 3rd speedgear I...

Page 53: ...rII 1 Installreversegearselectorrod 2 Install Special Tool 9106 and assemblereverse gears I and III 3 InstallreversegearII asshown in illustration 7 Adjustreversegearselectorrod 8 Adjustselectorrods s...

Page 54: ...the synchronizing rings in idle position 10 Torque hex head screwsof selector forks to specifications Note Correct deviations in adjustments after completion of shifting controls because they are esse...

Page 55: ...Mech gear shift system gears shafts TOOLS Remarks Designation Special Tool Nr Holder No 9104 1 Socket wrench No 9105 2 35 9 Printed in Germany Dismantling and Assembling Drive Shaft...

Page 56: ...35 Mech gear shift system gears shafts 35 10 Dismantling and Assembling Drive Shaft Printed in Germany...

Page 57: ...r 1 Replace in pairs only Facessame direction as countergear Thrust washer 1 Check synchro Replace in pairs only 3rd gear 1 8 Needle cage 9 Mark to in st ll correctly Assemblewith samegear 1 1 10 Spac...

Page 58: ...emove with sparesleeve Heatto ca 0 120 C and drive on 20 4 point bearing 1 21 Inner race 1 Remove with sparesleeve Heatto ca 0 120 C and drive on 22 Thrust washer 1 Remove with sparesleeve Groundside...

Page 59: ...ar 1 Clamp special tool no 9104 in a vise insert drive shaft and loosen nut with special tool no 9105 Assembling 1 Torquenut to specificationsandlock Note Special Tool 9105 cannot be usedto unscrewand...

Page 60: ...Manual Transmission Gears Shafts TOOLS Description Special Tool Remarks No No 9108 Guide sleeve 1 35 15 Disassembling and Assembling Drive Pinion Printed in Germany I 1976...

Page 61: ...35 Manual Transmission Gears Shafts Disassembling and Assembling Drive Pinion Printed in Germany 35 16...

Page 62: ...ssymmetricall y profiled teeth on 1stgear Note in stalled direction page35 18 8 Guide sleeve 1 9 2nd speedgear II 1 Check synchro replace in pairs only 10 2 11 Needle cage Sleeve 2nd speed 3rd speedge...

Page 63: ...g showsthe entire drive pinion without clamping plate for better understanding The parts up to and including number 14 are taken off and installed on an installed drive pinion refer to Removing and In...

Page 64: ...TOOLS...

Page 65: ...shafts Notes Designation Amt Remarks Removing Installing 1 Seal 1 Lubricateslightly 2 Seal 1 Remove with screwdriver Drive in to stop with pressuresleeve 3 Pipe 1 Printed in Germany Removing and Insta...

Page 66: ...for this purpose 1 Removeengine transmission assembly and unbolttransmission 2 Unscrew guidesleevecapscrews andremove guidesleeve Installing 1 Drive in seal to stop with piece of pipe 3 Pullout drive...

Page 67: ...ndsealinglip 4 Insert tube with rubber seal and seal 5 Install guide sleeve for release bearing and coat with MoS paste 2 6 Bolt transmissionto engine and install this assembly 35 22 Printed in German...

Page 68: ...ve with small screw driver Install correctly must fit properly 1 Lockwasher 2 1 Check for wear install correctly 3 Synchronizer ring 1 2 4 Stop Install correctly 5 Lock Install correctly 6 stop 1 Gear...

Page 69: ...Remove with small screw driver Install correctly must fit properly 2 Lockwasher 1 3 Synchronizing ring 1 Check for wear install correctly Stop 1 Install correctly 4 Lock Install correctly 5 1 6 Instal...

Page 70: ...on for 1st and 2nd gears has been changed 1 Insert synchronizing ring on clutch body in correct position and install lock stop and lock straps or just one lock strap for 1st gear 1 Synchronizer partsf...

Page 71: ...alled synchronizing ring with a micrometer Apply the micro meter at the highest position of the synchronizing ring Diameter 1st and 2nd gear 86 4 0 25 mm 3rd and 4th gear 76 3 0 17 mm 2 Max play betwe...

Page 72: ...39 Differential Final Drive TOOL Special Tool Remarks No Designation Pressurepad P 265 c 1 39 1 RemovingandInstalling Differential Printed in Germany...

Page 73: ...Differential Final Drive N Printed in Germany Removing and Installing Differential 39 2...

Page 74: ...to specifications Washer Replaceif necessary 5 12 Side cover Drive off with plastic hammer 6 1 7 Seal 1 Replace lubricate slightly Drive out punch Drive in with P 265 c 8 Shaft seal 1 9 1 Heat cover t...

Page 75: ...INSTRUCTIONS Removing 1 Loosenflange stretch bolt and remove flange Installing 0 1 Heat transmissioncover to about 120 C and drive in bearing outer race 2 Drive in flange seal with P265 c 39 4 Removin...

Page 76: ...TOOLS Remarks No Designation Special Tool P 264 b Pressurepad 1 P 263 2 Pressurepad Kukko No 20 1 3 Extracter Dismantling and Assembling Differential 39 5 Printed in Germany...

Page 77: ...Differential Final Drive Printed in Germany Dismantling and Assembling Differential 39 6...

Page 78: ...4 b 1 Magnetic support disc Watch magnetized parts Mark for reuse Determine thickness again if necessary 8 Shim x Mark for reuse Determine thickness again if necessary 9 1 Spacer Replace if necessary...

Page 79: ...ars between the large differential gears and turn until the gear bores align with the bores in the housing The claws of both arms must be machined 5 Install taperroller bearingwith P264b Assembling 1...

Page 80: ...TOOLS 3 1 Disassembling and Assembling Differential 39 8a Printed in Germany IlL 1978...

Page 81: ...Differential Final Drive 8 9 12 11 14 2 10 4 IV 1981 Printed in Germany Disassembling and Assembling Differential 39 8b...

Page 82: ...nner race 6 2 Knock on with P 264 Pull off with Kukko 20 1 and P 263 Magneticcarrier plate 1 Position correctly 8 Washer x Mark to install later If necessary deter mine thickness 9 Spacer Mark to inst...

Page 83: ...r differential pins Assembling 2 Pull off taperedroller bearinginnerraces with a puller e g KukkoNo 20 1 and specialtool P263 1 Mount ring gear using locally manufactured centering pins asguides A Cen...

Page 84: ...arge differential pinions with press fit threaded plates through large opening in differ ential housing and locate with joint flanges 6 Knock in differential pins in correct position and lock with spi...

Page 85: ...t running ashad been determined on special testing machines during production Absolute cleanliness is required during all assemblyand testing proceduresto attain good results Repairs on the final driv...

Page 86: ...keeping the ring gear within specified backlash tolerances The deviation r from the designdistance R is measuredand written on the face side of the drive pinion Ring gears and drive pinions are design...

Page 87: ...54 R 81 69 4 Commercial item 5 Commercial item 3 mm range VW 385 14 6 1 VW 385 56 30 mm long VW 385 17 8 Gaugeplate VW 387 9 Clock gauge holder Sleevf 9145 10 VW 521 4 Adjusting device VW 388 12 Meas...

Page 88: ...8 mm piece of pipe onto drive pinion 1 Deviation r in 1 100 mm 2 Pair code Examples N 18 is the deviation r on face of drive pinion R Design distance transm type 930 32 r Deviation 81 69 mm 0 18 mm 81...

Page 89: ...on case andside cover 10 Set adjusting ring of universal gauge VW 385 1 to distance a 14 Removemastergaugeafter setting dial gauge 15 Place gauge plate VW 385 17 on head of drive pinion about 58 mm 11...

Page 90: ...kness S 3 Example If small dial gauge needle is between 1 and 2 and large needle points to 0 37 mm with 1 mm dial gauge preload the shim thickness is 0 37 mm where by the thickness is always rounded o...

Page 91: ...e load of tapered roller bearing for differential 1 Make suretapered roller bearing outer races fit tight in transmissioncase or side transmis sioncover 2 Install pertinent differential with one each...

Page 92: ...cknessesto the available distance that the total shim thickness 81 and 82 is not changed 9 Remove differential pull off both tapered roller bearings and split up total shim thick ness 5 as follows Bec...

Page 93: ...ten all nuts to specified torque Note Whentightening nuts check frequently that there is still a certain amount of backlash Never let the drive pinion start to clamp 4 Screwgauge lever VW 388 and adju...

Page 94: ...achtime Measured values mustnotdeviateamongeachotherby more thanO 05 mm Note Backlashrequired is inscribed in ring gear 10 If specifiedbacklash is notreached change spacers 5 and5 again However do not...

Page 95: ...Differential Final Drive TOOLS Printed in Germany I 1976 Disassembling andAssembling Limited Slip Differential 39 21...

Page 96: ...Differential Final Drive Printed in Germany Disassembling and Assembling Limited Slip Differential 39 22...

Page 97: ...er 2 Insert properly Outer splined disc wavy 4 2 5 Outer splined disc 2 6 4 Inner splined disc molybdenum surface Outer splined disc 7 4 8 Pressurering 2 9 Gear 2 10 Threaded disc 2 Install properly P...

Page 98: ...splined discs and the inner splined disc serration should not be worn 2 Before installation lubricate all sliding surfaces of the discs the pressurerings and the differential shafts with hypoid gear l...

Page 99: ...and clamp one with two bolts inserted in a vise Install locally manufactured adaptor and turn differential with torque wrench Check that torque is 4 8 mkg 29 58 ft lb To meet or change the torque requ...

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