Porsche training p30 drivetrain repair sports car

® AfterSales Training Drivetrain Repair – Sports Cars P-30 Porsche AfterSales Training Student Name: Training Center Location: Instructor Name: Date: _ Important Notice: Some of the contents of this AfterSales Training brochure was originally written by Porsche AG for its restof-world English speaking market The electronic text and graphic files were then imported by Porsche Cars N.A, Inc and edited for content Some equipment and technical data listed in this publication may not be applicable for our market Specifications are subject to change without notice We have attempted to render the text within this publication to American English as best as we could We reserve the right to make changes without notice © 2010 Porsche Cars North America, Inc All Rights Reserved Reproduction or translation in whole or in part is not permitted without written authorization from publisher AfterSales Training Publications Dr Ing h.c F Porsche AG is the owner of numerous trademarks, both registered and unregistered, including without limitation the Porsche Crest®, Porsche®, Boxster®, Carrera®, Cayenne®, Cayman™, Panamera®, Tiptronic®, VarioCam®, PCM®, 911®, 4S®, FOUR, UNCOMPROMISED.SM and the model numbers and distinctive shapes of Porsche's automobiles such as, the federally registered 911 and Boxster automobiles The third party trademarks contained herein are the properties of their respective owners Specifications, performance standards, options, and other elements shown are subject to change without notice Some vehicles may be shown with non-U.S equipment Porsche recommends seat belt usage and observance of traffic laws at all times Printed in the USA Part Number - PNA P30 004 Edition - 2/10 Table of Contents Description Section Transmission Type Designations Boxster (986) Transmission Boxster & Cayman (987) Transmission 911 Turbo (996) Transmission 911 GT2/GT3 (996) Transmission Tiptronic Transmission Porsche Doppelkupplung (PDK) Transmission Final Drive Setup Conversion Charts Drivetrain Repair – Sports Cars Drivetrain Repair – Sports Cars Transmission Type Designations Transmission Number Identification Digit: 10 11 Example: G 0 Transmission Type: Transmission Version: Index of Variants: Serial Number: 911, Boxster and Cayman Transmission Type Designations Since Model Year 1989 Model Year Transmission Type Technical Data Installed In 1989 G50.00 G50.01 G50.02 G50.50 G64.00 G64.01 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 911 Carrera - RoW 911 Carrera - USA, Australia, Japan 911 Carrera - Switzerland 911 Turbo - World-Wide 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - Switzerland 1990 A50.01 G50.03 G50.04 G64.00 G64.01 4-Speed A/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - Switzerland 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - Switzerland 1991 A50.01 G50.03 G50.04 G50.52 G64.00 G64.01 4-Speed A/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - Switzerland 911 Turbo (964) - World-Wide 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - Switzerland 1992 A50.02 A50.03 G50.03 G50.04 G50.05 G50.10 G50.52 G64.00 G64.01 G64.02 4-Speed A/T 4-Speed A/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 911 Carrera (964) - RoW 911 Carrera (964) - USA/Canada 911 Carrera (964) - RoW 911 Carrera (964) - Switzerland 911 Carrera (964) - USA/Canada 911 Carrera RS (964) - RoW 911 Turbo (964) - World-Wide 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - Switzerland 911 Carrera (964) - Taiwan Drivetrain Repair – Sports Cars Page 1.1 Transmission Type Designations Model Year Transmission Type Technical Data 1993 A50.02 A50.03 G50.03 G50.04 G50.05 G50.10 G64.00 G64.01 G64.02 4-Speed A/T 4-Speed A/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 911 Carrera (964) - RoW 911 Carrera (964) - USA/Canada, Taiwan 911 Carrera (964) - RoW 911 Carrera (964) - Switzerland/Taiwan 911 Carrera (964) - USA/Canada 911 Carrera RS (964) - RoW 911 Carrera (964) - RoW, USA 911 Carrera (964) - Switzerland 911 Carrera (964) - Taiwan 1994 A50.02 A50.03 G50.03 G50.04 G50.05 G50.10 G50.52 G64.00 G64.01 G64.02 4-Speed A/T 4-Speed A/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 911 Carrera (964) - RoW 911 Carrera (964) - USA/Canada, Taiwan 911 Carrera (964) - RoW 911 Carrera (964) - Switzerland/Taiwan 911 Carrera (964) - USA/Canada 911 Carrera RS (964) - RoW 911 Turbo 3.6 (964) - World-Wide 911 Carrera (964) - RoW, USA 911 Carrera (964) - Switzerland 911 Carrera (964) - Taiwan 1995 A50.04 A50.05 G50.20 G50.21 4-Speed A/T 4-Speed A/T 6-Speed M/T 6-Speed M/T 911 Carrera (993) - RoW 911 Carrera (993) - USA/Canada, Taiwan 911 Carrera (993) - USA/Canada 911 Carrera (993) - RoW 1996 A50.04 A50.05 G50.20 G50.21 G64.20 G64.21 G64.51 4-Speed A/T 4-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 911 Carrera (993) - RoW 911 Carrera (993) - USA/Canada, Taiwan 911 Carrera (993) - USA/Canada 911 Carrera (993) - RoW 911 Carrera (993) - USA/Canada 911 Carrera (993) - RoW 911 Turbo (993) - World-Wide 1997 A50.04 A50.05 G50.20 G64.20 G64.51 A86.00 G86.00 4-Speed A/T 4-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed M/T 911 Carrera (993) - RoW 911 Carrera (993) - USA/Canada, Taiwan 911 Carrera (993) - RoW, USA/Canada 911 Carrera (993) - RoW, USA/Canada 911 Turbo (993) - World-Wide Boxster (986) Boxster (986) 1998 A50.04 A50.05 G50.20 G64.20 G64.42 G64.51 A86.00 G86.00 4-Speed A/T 4-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed M/T 911 Carrera (993) - RoW 911 Carrera (993) - USA/Canada, Taiwan 911 Carrera (993) - RoW, USA/Canada 911 Carrera 4/4S (993) - RoW, USA/Canada 911 Turbo (993) - Taiwan 911 Turbo (993) - RoW, USA/Canada Boxster (986) Boxster (986) Page 1.2 Installed In Drivetrain Repair – Sports Cars Transmission Type Designations Model Year Transmission Type Technical Data Installed In 1999 A86.00 G86.00 A96.00 A96.30 G96.00 G96.30 5-Speed A/T 5-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T Boxster (986) Boxster (986) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 2000 A86.05 A86.20 G86.01 G86.20 A96.00 A96.30 G96.00 G96.30 G96.90 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T Boxster (986) Boxster S (986) Boxster (986) Boxster S (986) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 GT3 (996) - RoW 2001 A86.05 A86.20 G86.01 G86.20 A96.00 A96.30 G96.00 G96.30 G96.50 A96.50 G96.88 G96.90 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T Boxster (986) Boxster S (986) Boxster (986) Boxster S (986) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Turbo (996) - World-Wide 911 Turbo (996) - World-Wide 911 GT2 (996) - World-Wide 911 GT3 (996) - RoW 2002 A86.05 A86.20 G86.01 G86.20 A96.10 A96.35 G96.01 G96.31 G96.50 A96.50 G96.88 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T Boxster (986) Boxster S (986) Boxster (986) Boxster S (986) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Turbo (996) - World-Wide 911 Turbo (996) - World-Wide 911 GT2 (996) - World-Wide Drivetrain Repair – Sports Cars Page 1.3 Transmission Type Designations Model Year Transmission Type Technical Data 2003 A86.05 A86.20 G86.01 G86.20 A96.10 A96.35 G96.01 G96.31 G96.50 A96.50 G96.88 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T Boxster (986) Boxster S (986) Boxster (986) Boxster S (986) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Turbo (996) - World-Wide 911 Turbo (996) - World-Wide 911 GT2 (996) - World-Wide 2004 A86.05 A86.20 G86.01 G86.20 A96.10 A96.35 G96.01 G96.31 G96.50 A96.50 G96.88 G96.96 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T Boxster (986) Boxster S (986) Boxster (986) Boxster S (986) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Turbo (996) - World-Wide 911 Turbo (996) - World-Wide 911 GT2 (996) - World-Wide 911 GT3 (996) - USA/Canada 2005 A87.01 A87.20 G87.01 G87.20 A96.10 A96.35 G96.01 G96.31 A97.01 G97.01 G96.50 A96.50 G96.88 G96.96 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T Boxster (987) Boxster S (987) Boxster (987) Boxster S (987) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera/S (997) - RoW, USA/Canada 911 Carrera/S (997) - RoW, USA/Canada 911 Turbo (996) - World-Wide 911 Turbo (996) - World-Wide 911 GT2 (996) - World-Wide 911 GT3 (996) - USA/Canada 2006 A87.01 A87.20 G87.01 G87.20 A87.21 G87.21 A97.01 G97.01 A97.31 G97.31 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 5-Speed A/T 6-Speed M/T Boxster (987) Boxster S (987) Boxster (987) Boxster S (987) Cayman S (987) Cayman S (987) 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada Page 1.4 Installed In Drivetrain Repair – Sports Cars Transmission Type Designations Model Year Transmission Type Technical Data Installed In 2007 A87.02 A87.21 G87.01 G87.21 A87.02 A87.21 G87.01 G87.21 A97.01 G97.01 A97.31 G97.31 G97.50 A97.50 G97.90 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T Boxster (987) Boxster S (987) Boxster (987) Boxster S (987) Cayman (987) Cayman S (987) Cayman (987) Cayman S (987) 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Turbo (997) - World-Wide 911 Turbo (997) - World-Wide 911 GT3 (997) - USA/Canada 2008 A87.02 A87.21 G87.01 G87.21 A87.02 A87.21 G87.01 G87.21 A97.01 G97.01 A97.31 G97.31 G97.50 A97.50 G97.88 G97.90 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T Boxster (987) Boxster S (987) Boxster (987) Boxster S (987) Cayman (987) Cayman S (987) Cayman (987) Cayman S (987) 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Turbo (997) - World-Wide 911 Turbo (997) - World-Wide 911 GT2 (997) - World-Wide 911 GT3 (997) - USA/Canada 2009 CG2.00 CG2.20 G87.10 G87.40 CG2.00 CG2.20 G87.10 G87.40 CG1.00 G97.05 CG1.30 G97.35 G97.50 A97.50 G97.88 7-Speed PDK 7-Speed PDK 6-Speed M/T 6-Speed M/T 7-Speed PDK 7-Speed PDK 6-Speed M/T 6-Speed M/T 7-Speed PDK 6-Speed M/T 7-Speed PDK 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T Boxster (987) Boxster S (987) Boxster (987) Boxster S (987) Cayman (987) Cayman S (987) Cayman (987) Cayman S (987) 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Turbo (997) - World-Wide 911 Turbo (997) - World-Wide 911 GT2 (997) - World-Wide Drivetrain Repair – Sports Cars Page 1.5 Transmission Type Designations Model Year Transmission Type Technical Data 2010 CG2.00 CG2.20 G87.10 G87.40 CG2.00 CG2.20 G87.10 G87.40 CG1.00 G97.05 CG1.30 G97.35 G97.55 CG1.50 G97.90 7-Speed PDK 7-Speed PDK 6-Speed M/T 6-Speed M/T 7-Speed PDK 7-Speed PDK 6-Speed M/T 6-Speed M/T 7-Speed PDK 6-Speed M/T 7-Speed PDK 6-Speed M/T 6-Speed M/T 7-Speed PDK 6-Speed M/T Page 1.6 Installed In Boxster (987) Boxster S (987) Boxster (987) Boxster S (987) Cayman (987) Cayman S (987) Cayman (987) Cayman S (987) 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Turbo (997) - World-Wide 911 Turbo (997) - World-Wide 911 GT3 (997) - World-Wide Drivetrain Repair – Sports Cars PDK Transmission PDK Shift-Lever Interface Engine off: Serial line is used for communication (gear position from instrument cluster) Engine running: CAN bus is utilized for communication Instrument Cluster Gateway CAN Drive Serial Communication Shift Lever Control Unit Control For Key/Shift Lock Transmission Control Unit Mechanical Linkage For Park Lock Notes: Page 7.22 Drivetrain Repair – Sports Cars Final Drive Setup Subject Page Adjusting Drive Pinion Set – Boxster Adjusting Drive Pinion Set – 911 Turbo (993) Drivetrain Repair – Sports Cars Page 8.1 Final Drive Setup Notes: Page 8.2 Drivetrain Repair – Sports Cars Final Drive Setup – Boxster Adjusting Final Drive – Boxster G 86 General Careful adjustment of the pinion shaft and ring gear are crucial to the service life and smooth running of the final drive Therefore, pinion shafts and ring gears are paired with each other during the manufacturing process and are checked by special inspection machines to ensure that the tooth contact is in the optimum position and that there is low noise in both rotation directions The deviation “r”referred to the master gauge “Ro” is measured for the drive sets supplied as spare parts and is recorded on the outer circumference of the ring gear Every drive set (ring and pinion) must be replaced as a set Adjustment and Marking of the Drive Sets (G 86) Drive Sets Installed In New Vehicles Note In the series, the position of the pinion shaft is determined by the dimension Po (center of the ring gear to the rear of the pinion shaft head) The markings of the deviation “r” on the ring gear and the pairing number are not present Due to the deviation “r” not being given, it is necessary that, before the pinion shaft is replaced, to carry out an actual measurement if the parts are being replaced which directly influence the installation position of the pinion shaft X – These details are not required in the series Po – Adjustment dimension for the series Notes: KD Drive Sets Identification”0937” means Oerlikon drive set with the transmission ratio of 35:9 Pairing number (312) of the drive set Deviation “r” referred to the master gauge of the special inspection machine used in production The deviation “r” is always stated in 1/100 mm Example: “25” means r = 0.25mm Ro – Length of the used master gauge of the special inspection machine “Ro” = 59.65 mm R – Actual dimension between the ring gear axis and the front side of the pinion shaft at the point of maximum smooth running for this drive set Vo – Hypoid offset Drivetrain Repair – Sports Cars Page 8.3 Final Drive Setup – Boxster Adjustment Overview When carrying out assembly work on the final drive, readjustment of the ring and pinion is necessary only if parts are being replaced which directly influence the adjustment of the final drive In order to avoid unnecessary adjustment work, observe the following chart: * If the transmission housing is replaced, it is also necessary to adjust the input shaft Notes: Page 8.4 Drivetrain Repair – Sports Cars Final Drive Setup – Boxster Appropriate Sequence For Readjusting Drive Set Determining The Installation Position Of The Pinion Shaft (Actual Measurement) This procedure must be carried out only if the deviation “r” is not given on the ring gear and if parts are to be replaced which directly influence the pinion shaft position These are: both tapered roller bearings for the drive pinion and the transmission housing Remove the differential, complete the universal measuring mandrel, as described in the Boxster Technical Manual 3922 Insert it into the transmission housing and measure the difference to “Ro” (max deflection/reversing point) The measured value corresponds to the deviation “r” Note the value S1 S2 S3 S4 = = = = Adjusting shim for ring gear Adjusting shim for ring gear Adjustment shim for pinion shaft Adjustment shim for pinion shaft After replacing the parts, adjust the pinion shaft as described When doing so, use the deviation “r” determined when measuring the adjusting shim “S3” Notes: If the pinion shaft and ring gear have to be adjusted, it is best to follow the following sequence: Determine the total disc thickness “Stot” )S1 plus S2) for the correct preload of the tapered roller bearings differential Determine the total disc thickness “Stot” (S3 plus S4) for the correct preload of the tapered roller bearings pinion shaft Divide up the total disc thickness “Stot” in S3 and S4 so that the measurement from the ring gear center to the front of the drive pinion corresponds to the installation dimension “R” measured during production Divide up the total disc thickness “Stot” in S1 and S2 so that the stipulated circumferential backlash is present between the ring gear and pinion shaft The goal of the adjustment is to again achieve the position of maximum smooth running which was determined in production on the testing machine The greatest possible care and cleanliness during the assembly process are required to assure adjustment accuracy Drivetrain Repair – Sports Cars Page 8.5 Final Drive Setup – 911 Turbo (993) Adjusting Final Drive – 911 Turbo (993) General In this section we cover final drive setup using a 911 Turbo (993) model This information is general and intended to demonstrate proper technics and tools when installing and setting up a differential All the specifications and processes listed in this section are for training purposes only Always consult the individual model’s technical manual when performing final drive setup The settling of drive pinion and ring gear is a determining factor for the service life and smooth running of the rearaxle drive Drive pinions and ring gears 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, whereby the ring gear is kept within the tolerance of the prescribed tooth backlash and is engraved on ring gear as setting dimension “E” The Porsche Special Tools listed in this section are noted in Bold type (example 9150) Information regarding Porsche Special Tools can be found in the Special Tool Catalog, part number, PNA 721 032 Ring and Pinion Values E = Design dimension = Setting dimension “E” (e.g 70.32 mm) = Circumferential backlash “F” (e.g 0.14 mm) = Matching number Adjusting Drive Pinion – Setting value “E” (70.32 mm) Final Drive Adjustment Points - Shim S1 - Shim S2 - Adjusting shim S3 E - Setting value Correct results may only be achieved if assembly work and measuring procedures are carried out carefully and with maximum cleanliness Notes: The “1” Setting Value “E” Is Indicated On The Ring Gear Install complete gear set without “S3” shims and tighten all tensioning plate hexagon-head nuts to 23 Nm (17 ftlb.) Fit gear housing and locate with three nuts Install and engage sixth gear Block input shaft with Special Tool 9253 and tighten drive pinion collar nut to 300 Nm (221 ftlb.) Page 8.6 Drivetrain Repair – Sports Cars Final Drive Setup – 911 Turbo (993) Adjusting Drive Pinion (cont’d) Fit lateral transmission cover without O-ring and tighten crosswise with nuts Suitable Pipe Section (A) Set adjusting ring of measuring mandrel VW 385/1 to dimension “a” Note: Do not use a hammer when fitting the lateral transmission cover (the gauge block plate held by magnets might fall off) Fit cover in installation position only by tightening the nuts uniformly Notes: A = approx 65 mm Assemble measuring mandrel with centering disks 9109, tapered roller bearing, plunger VW 385/14 and dial gauge extension 9150 Set special tool measuring mandrel with master gauge 385/30 to the setting value (61.43 mm in the example) Set dial gauge (3 mm measuring range) to zero with mm preload Put gauge block plate 9281 on drive pinion head and insert measuring mandrel into transmission case Dial gauge extension is located in the area of the gauge block plate Drivetrain Repair – Sports Cars Page 8.7 Final Drive Setup – 911 Turbo (993) Adjusting Drive Pinion (cont’d) Adjusting Ring Gear 10 Pull second centering disk with spindle towards the outside until the measuring mandrel can just be turned by hand Determine total shim thickness “S tot.” (S1 + S2) The ring gear must be adjusted, if the: Transmission case, lateral transmission cover, tapered roller bearing for differential, differential housing or drive set have not been replaced Note: The drive pinion must be removed to determine the preload of the differential tapered roller bearings Make sure that the bearing outer races of the tapered roller bearings are well seated in the transmission case or lateral transmission cover, respectively Fit one spacer ring (2.5 mm thick) on the ring gear side and on the opposite side of the differential to be used 11 Turn measuring mandrel carefully until the dial gauge extension is vertical to the face of the drive pinion head At this point, the pointer of the dial gauge reaches maximum deflection (reverse point) and the dial gauge must be read Note: The measured value always deviates from the set dimension clockwise (the smaller pointer on the dial gauge is between and 2), i.e if the dial gauge is set with a preload of mm, the value deviating from is taken as shim thickness “S3” Insert differential into transmission case and rotate several times Fit lateral transmission cover without seal and tighten all hexagon-head nuts to 23 Nm (17 ftlb.) Put gauge block plate VW 385/17 on the collar of the differential Fasten universal dial gauge holder VW 387 with dial gauge and extension to the case and set to with mm preload Example: If the small pointer on the dial gauge is between and and the large pointer indicates 0.37 mm, then 0.37 mm is the shim thickness (with mm gauge preload) to be inserted Always round up or down to the nearest 0.05 mm (e.g 0.37 mm to 0.35 mm) 12 After inserting the necessary shims, check the setting value “E” again A deviation of ± 0.03 mm is permissible A = Dial gauge extension (approx 30 to 40 mm long) B = Gauge block plate VW 385/17 Move differential up and down Read off backlash on the dial gauge and note Note: Do not turn differential while measuring backlash as this will give an incorrect reading Page 8.8 Drivetrain Repair – Sports Cars Final Drive Setup – 911 Turbo (993) Adjusting Ring Gear (cont’d) Adjusting Circumferential Backlash Calculate “S tot.” “S tot.” = Fitted shim thickness + Measured value + Pressure fit of tapered roller bearing Note: The backlash to be set is embossed on the ring gear Mount gear set using shims “S3” determined while adjusting the drive pinion Example Thickness of shims inserted Measured value Pressing (constant value) “S tot.” 5.00 mm 0.75 mm 0.40 mm 6.15 mm Remove differential, pull off both tapered roller bearings and split calculated shim thickness “S tot.” as follows Select spacer S1 0.70 mm thinner and S2 0.70 mm thicker as a starting point for subsequent adjustment of the backlash Insert differential with tapered roller bearing and shims (S1 + S2) into the housing Fit lateral transmission cover and tighten all hexagonhead nuts to 23 Nm (17 ftlb.) Note: Always make sure that there is a certain amount of backlash when tightening the nuts Never allow the drive pinion to seize Example: Total shim thickness of spacers = 6.15 mm S1 + S2 Assemble measuring lever VW 388 and adjusting device VW 521/4 and adjust lever length to 91 mm with the plunger Refer to dimension “a” in the illustration Thickness of spacer S1 6.15 mm Note: Make sure that the collar nut of the drive pinion is tightened to 300 Nm (221 ftlb.) before measuring backlash = 3.075 mm - 0.700 mm 2.375 mm Insert adjusting device with clamping sleeve 9145 into the differential and clamp firmly Thickness of spacer S2 6.15 mm Rotate differential in both directions several times to settle the tapered roller bearings = 3.075 mm + 0.700 mm 3.775 mm Note: Spacers are available in thicknesses of 1.6 to 3.1 mm in increments of 010 mm By using a 0.25 mm shim, the shim thicknesses may be graduated in increments of 0.05 mm, Fit universal dial gauge holder with flat extension in such a way as to produce a right angle between dial gauge axis and lever The calculated shim thicknesses must be rounded up or down for plausible dimensions that will not alter the total thickness S1 and S2 Example: Calculated thicknesses S1 + S2 = 2.375 + 3.775 = 6.15 mm Rounded thicknesses S1 + S2 = 2.35 + 3.80 = 6.15 mm Measure shims with a micrometer in several places Permissible deviation 0.02 mm Also check shims for burrs and damage Dimension “a” = approx 91 mm Drivetrain Repair – Sports Cars Page 8.9 Final Drive Setup – 911 Turbo (993) Turn ring gear carefully at the clamping screw of the adjusting device as far as the stop and set the dial gauge to zero Turn back ring gear and read off circumferential backlash Write down the reading Notes: Note: When carrying out measurements, the drive pinion must be blocked with Special Tool 9576 After turning the ring gear a further 90° repeat measuring procedures three times The measured values must not deviate from one another by more than 0.05 mm Note: The backlash to be adjusted is embossed on the ring gear A deviation of ± 0.03 mm is admissible 10 If the required backlash cannot be obtained, replace spacers (S1 + S2) again The total shim thickness (“S tot.”) must not be altered, however Page 8.10 Drivetrain Repair – Sports Cars Conversion Charts Temperature Conversion Metric Conversion Formulas INCH X MM X MILE X KM(KILOMETER) X OUNCE X GRAM X POUND(lb) X kg(KILOGRAM) X CUBIC INCH X cc(CUBIC CENTIMETER) X FOOTPOUND(ft lb) X Nm(NEWTON METER) X HORSEPOWER(SAE) X HORSEPOWER(DIN) X Kw(KILOWATT) X HORSEPOWER(SAE) X MPG(MILES PER GALLON) X BAR X PSI(POUND SQUARE INCH) X GALLON X LITER X FAHRENHEIT CELSIUS X 25.4 0394 1.609 621 28.35 0352 454 2.2046 16.387 061 1.3558 7376 746 9861 1.34 1.014 4251 14.5 0689 3.7854 2642 32÷1.8 1.8+32 Drivetrain Repair – Sports Cars = = = = = = = = = = = = = = = = = = = = = = = MM INCH KILOMETER(KM) MILE GRAM OUNCE KILOGRAM(kg) lb(POUND) CUBIC CENTIMETER(cc) CUBIC INCH NEWTON METER(Nm) ft lb(FOOT POUND) KILOWATT(Kw) HORSEPOWER(SAE) HORSEPOWER(SAE) HORSEPOWER(DIN) Km/l(KILOMETER PER LITER) POUND/SQ INCH(PSI) BAR LITER GALLON CELSIUS FAHRENHEIT Page 9.1 Conversion Charts Notes: Page 9.2 Drivetrain Repair – Sports Cars Part Number - PNA P30 004 ... Conversion Charts Drivetrain Repair – Sports Cars Drivetrain Repair – Sports Cars Transmission Type Designations Transmission Number Identification... longer clutch service life Page 4.2 Drivetrain Repair Sports Cars 911 Turbo (996) Transmission G96.50 Transmission Cutout Notes: Drivetrain Repair – Sports Cars Page 4.3 911 Turbo (996) Transmission... is used on both 911 GT2/GT3 models Drivetrain Repair – Sports Cars 911 GT2/GT3 Transmission G96.88/96 Transmission Cutout Notes: Drivetrain Repair – Sports Cars Page 5.3