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Porsche 911 TURBO - 1989, Руководство пользователя

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Porsche 911 TURBO - 1989 Скачать руководство пользователя страница 1

Содержание 911 TURBO - 1989

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 64: ...TOOLS...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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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