® AfterSales Training Drivetrain Repair – Sports Cars 911 (996)/Boxster “S” (986) 6-Speed Manual Transmission P30G Porsche AfterSales Training Student Name: Training Center Location: Instructor Name: Date: _ Important Notice:The contents of this AfterSales Training brochure was originally written by Porsche AG for its rest-of-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 © 2007 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®, CaymanTM, Tiptronic®, VarioCam®, PCM®, 911®, 4S®, and the model numbers and distinctive shapes of Porsche’s automobiles such as, the federally registered 911 automobile The third party trademarks contained herein are the properties of their respective owners Porsche Cars North America, Inc., believes the specifications to be correct at the time of printing However, specifications, standard equipment and options are subject to change without notice Part Number - PNA P30 G01 Edition - 4/07 Table of Contents Description Section Transmission Type Designations Six-Speed Transmissions – G96.00/01/30/31, G86.20 Final Drive Setup Conversion Charts Drivetrain Repair – Sports Cars 6-Speed Drivetrain Repair – Sports Cars 6-Speed 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 6-Speed 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 6-Speed 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 6-Speed 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 6-Speed 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 Drivetrain Repair – Sports Cars 6-Speed Page 1.5 Transmission Type Designations Page 1.6 Drivetrain Repair – Sports Cars 6-Speed 911 (996)/Boxster S (986) Transmission Notes: Page 2.16 Drivetrain Repair – Sports Cars 6-Speed Final Drive Setup Subject Page Required Tools Adjusting Overview Determining Total Shim Thickness S1 & S2 Determining Total Shim Thickness S3 & S4 Dividing Total Shim Thickness S3 + S4 into S3 & S4 Determining Total Shim Thickness S5 Dividing Total Shim Thickness S1 + S2 into S1 & S2 Checking Circumferential Backlash Drivetrain Repair – Sports Cars 6-Speed Page 3.1 Final Drive Setup Notes: Page 3.2 Drivetrain Repair – Sports Cars 6-Speed Final Drive Setup Adjusting Final Drive Adjustment Overview Required Tools When carrying out assembly work on the final drive, readjustment of the ring and pinion or drive set is necessary only if parts are being replaced which directly influence the adjustment of the final drive In order to avoid unnecessary adjustment work, follow the following table: Adjusting Shims Replaced Parts to be Determined Transmission housing S1, S2, S3, S4, S5, S6 Differential Key Description S1, S2 Taper roller bearing for the differential S1, S2 Tool Number Cover for final drive S1, S2 S1, S2, S3, S4, S5 A Measuring mandrel VW 385/1 Drive set B Centering sleeve 9109 Angular-contact ball bearing for output shaft S3, S4 , S5 C Universal master gauge VW 385/30 Angular-contact ball bearing for drive shaft D Digital depth gauge Commercially available E Dial gauge Commercially available F Gauge plunger VW385/14 G Final-dimension plate VW 385/33 H Adjusting shim, 50 mm VW 385/17 I Dial gauge holder VW387 J Clamping bush 9145 K Adjustment device VW521/4 L Measuring lever VW 388 M Gauge plunger VW 388 N Micrometer Commercially available O Measuring device 9694/8 S6 Sequence of Adjustment Operations If the ring and pinion have to be adjusted, it is best to follow the sequence below in the interest of rational working: General Information Careful adjustment of the ring and pinion are crucial to the service life and smooth running of the final drive Therefore, ring and pinions are paired with each other early in the production process and are checked by special machines to ensure a good contact pattern Determine the total shim thickness S1 + S2 Calculate the total shim thickness S3 + S4 Divide the total shim thickness S3 + S4 into S3 and S4 Determine the shim thickness S5 Determine the shim thickness S6 Divide the total shim thickness into S1 and S2 Check the circumferential backlash and adjust it if necessary Drivetrain Repair – Sports Cars 6-Speed Page 3.3 Final Drive Setup Preliminary Work Remove transmission ❙ ✁orkshop Manual > 343519 Installing and removing transmission G96.00/01 Drain transmission oil See Workshop Manual > 340155 Changing transmission oil Disassemble the transmission See Workshop Manual > 343537 Disassembling and assembling transmission Determining Total Shim Thickness S1 + S2 Note! > The output shaft must be removed in order to determine the total shim thickness S1 + S2 > Before beginning adjustment and measuring work, the sealing surfaces of the transmission housing and cover must be cleaned carefully Place the final dimension plate, 50 mm VW 385/17 on the differential, fit dial gauge holder VW 387 and clamp dial gauge Turn the differential several times at the adjustment device VW 521/4 and set the dial gauge with mm pretension to Insert adjusting shims S1 and S2 with a thickness of 1.5 mm each under the taper roller bearing and fit the taper roller bearing Insert differential in transmission housing Fit transmission cover without a shaft sealing ring and screw in screws Tightening torque: 19 ftlb (25 Nm) Press the differential towards the transmission cover at the adjustment device VW 521/4 and read off the play on the dial gauge Example: 1.00 mm The total thickness of shims S1+S2 is calculated from the total of the already inserted shims plus the measured value plus the specified bearing pretension of the taper roller bearing Fit the adjustment device VW 521/4 and bushing 9145 in the differential Example: 3.00 mm + 1.00 mm + 0.20 mm = 4.20 mm = S1 + S2 Note! The pretension of the taper roller bearing in this transmission is always 0.20 mm Page 3.4 Drivetrain Repair – Sports Cars 6-Speed Final Drive Setup Determining Total Shim Thickness S3 + S4 Note! Use a digital depth gauge to measure the depth of the bearing bore To this, measure the depth at three different positions and work out the mean value The bearing pretension v1 for this bearing is always 0.20 mm Example: Insert angular-contact ball bearing into the measuring device 9694/8 (sides B facing the bearing) and tighten the screw Tightening torque: 7.5 ftlb (10 Nm) Measure dimension h1 between the turned groove and outer bearing ring using a micrometer • Measurement 1: 34.40 mm • Measurement 2: 34.44 mm • Measurement 3: 34.42 mm Depth of bore T1 = 34.40 mm + 34.44 mm + 34.42 mm = 103.26 mm/ = 34.42 mm Notes: Take a measurement at each cut-out of the measuring device 9694/8 and find the mean value • Measurement 1: 34.40 mm • Measurement 2: 34.41 mm • Measurement 3: 34.39 mm Bearing height h1 = 34.40 mm + 34.41 mm + 34.39 mm = 103.20 mm/ = 34.40 mm Drivetrain Repair – Sports Cars 6-Speed Page 3.5 Final Drive Setup Use a digital depth gauge to measure the depth of the turned groove in the tensioning plate To this, measure the depth at three different positions and work out the mean value Dividing Total Shim Thickness S3 + S4 into S3 & S4 Fit angular-contact ball bearing on output shaft See Workshop Manual >343537 Disassembling and assembling transmission Insert output shaft with angular-contact ball bearing with adjusting shim S3 = 1.00 mm (empirical value) into transmission housing See Workshop Manual >343537 Disassembling and assembling transmission Work out the provisional shim thickness S4 using the value (S3 + S4) calculated in the previous section Example: Example: S4 = 1.94 mm - 1.00 mm = 0.94 mm ≈ 0.95 mm • Measurement 1: 34.40 mm • Measurement 2: 34.44 mm • Measurement 3: 34.42 mm Insert adjusting shim S4 into tensioning plate and secure tensioning plate bolts in the correct sequence Depth of groove t1 = 1.76 mm + 1.82 mm + 1.70 mm = 5.28 mm/ = 1.76 mm The total shim thickness S3 + S4 is determined as follows: (S3 + S4) = T1 + v1 + t1 - h1 Example: • • • • T1 = 34.40 mm v1 = 0.20 mm t1 = 1.76 mm h1 = 34.42 mm Tightening sequence for tensioning plate bolts Tightening torque: 24 ftlb (32 Nm.) (S3 + S4) = 34.40 mm + 0.20 mm + 1.76 mm - 34.42 mm = 1.94 mm Set the setting collar on special tool measuring mandrel VW 385/1 to the dimension a (approx 60 mm) Since the adjusting shims are only available in increments of 0.05 mm, the value must be rounded off accordingly (S3 + S4) = ≈ 1.95 mm Page 3.6 Drivetrain Repair – Sports Cars 6-Speed Final Drive Setup Complete the measuring mandrel as shown in the illustration 13 Turn the measuring mandrel carefully back and forth until the reversing point on the dial gauge is reached At this point, the dial gauge extension is positioned exactly at right angles to the front face of the pinion head 14 Read off the deviation from the specified adjusting value E If the deviation is greater than 0.04 mm, an adjustment is required Example: 0.10 mm Read off the installation dimension E from the crown wheel Note! So in the example, the actual value of the adjusting dimension E would not be 61.55 but rather 61.65 mm Example: E = 61.55 mm Set the installation dimension E on special tool universal master gauge VW 385/30 and set the dial gauge to with mm pretension 15 In order to achieve the required adjusting dimension E, the adjusting shim S3 must be adjusted by the measured value Example: New shim thickness S3 = 0.90 mm Note! The transmission must be allowed to cool down completely before starting to insert measuring devices Place special tool final-dimension plate VW 385/33 on the pinion head of the output shaft 10 Insert the measuring mandrel as shown in the illustration 16 In order to adjust the altered washer S3, washer S4 must be altered in the opposite direction by the determined value Example: S4 = 1.05 mm (increase by 0.10 mm) 17 When the shims S3 and S4 have been corrected appropriately and inserted, the adjusting dimension E should be checked again Notes: 11 Place the side transmission cover in position without an O-ring and pull downwards with screws Do not use force Tightening torque: 19 ftlb (26 Nm) 12 Press taper roller bearing with the centering screw over the spindle into the bearing shells It should just be possible to turn the measuring mandrel by hand Drivetrain Repair – Sports Cars 6-Speed Page 3.7 Final Drive Setup Take a measurement at each cut-out of the measuring device 9694/8 and find the mean value Determining Shim Thickness S5 The thickness of the adjusting shim S5 is calculated from the thickness of the bearing bore T1, the thickness of adjusting shim S3, the bearing height h1 and the specified distance between the transmission front face and the front face of the hub of fixed gear wheel for 4th gear (2 mm) S5 = T1 + - S3 - h1 • Measurement 1: 33.97 mm • Measurement 2: 33.93 mm • Measurement 3: 33.95 mm Bearing height h2 = 33.97 mm + 33.93 mm + 33.95 mm = 101.85 mm/ = 33.95 mm Example: Use a digital depth gauge to measure the depth of the bearing bore To this, measure the depth at three different positions and work out the mean value • h1 = 34.40 mm • S3 = 0.90 mm • T1 = 34.42 mm S5 = 34.42 mm + mm - 0.90 mm - 34.40 mm = 1.12 mm Determining Shim Thickness S6 Note! The transmission The bearing pretension v2 for this bearing is always 0.10 mm Example: Insert angular-contact ball bearing into the measuring device 9694/8 (sides A facing the bearing) and tighten the screw • Measurement 1: 34.40 mm • Measurement 2: 34.20 mm • Measurement 3: 34.30 mm Depth of bore T2 = 34.40 mm + 34.20 mm + 34.30 mm = 102.90 mm/ = 34.30 mm The adjusting shim thickness S6 is determined as follows: Tightening torque: 7.5 ftlb (10 Nm) Measure dimension h2 between the outer bearing rings using a micrometer S6 = T2 - h2 + v2 Example: • h2 = 33.95 mm • v2 = 0.10 mm • T2 = 34.30 mm S6 = 34.30 mm - 33.95 mm + 0.1 mm = 0.45 mm Page 3.8 Drivetrain Repair – Sports Cars 6-Speed Final Drive Setup Dividing The Total Shim Thickness S1 + S2 into S1 and S2 Insert adjusting shim S4 into the tensioning plate and secure tensioning plate screws in the correct sequence Note! In order to gain as precise a setting of the backlash as possible at this point, the total adjusting shim thickness S1 + S2 must be divided equally Example: Shim thickness S1 = 4.20 mm/2 = 2.1 mm Example: Shim thickness S2 = 4.20 mm/2 = 2.1 mm Note! As the adjusting shims are available in thicknesses from 1.5 to 2.8 mm in increments of 0.05 mm, the calculated result may have to be rounded off However, the total of the shim thicknesses S1 + S2 must not be changed To determine the thickness, measure the adjusting shims at several positions using a micrometer Also check the shims for burrs and signs of damage Remove the differential and pull off both taper roller bearings Tightening sequence for tensioning plate bolts Tightening torque: 24 ftlb (32 Nm) Assemble differential and insert it into the transmission housing See Workshop Manual > 390937 Disassembling and assembling differential Place the side transmission cover in position without an O-ring and pull downwards with bolts Do not use force Tightening torque: 19 ftlb (26 Nm) Insert the calculated adjusting shims S1 and S2 Checking Circumferential Backlash Read off the backlash from the ring gear Note! Always make sure a certain amount of backlash is present when tightening the bolts The drive pinion must not jam under any circumstances Notes: Example: F = 0.15 mm Insert output shaft with angular-contact ball bearing with adjusting shim S3 into the transmission housing See Workshop Manual > 343537 Disassembling and assembling transmission Drivetrain Repair – Sports Cars 6-Speed Page 3.9 Final Drive Setup Screw in special tool gauge plunger VW 388 with special tool adjustment device VW 521/4 and set the lever length to 68 mm -a- Notes: Insert special tool adjustment device VW 521/4 into the differential with special tool bushing 9145 and clamp tight Turn the differential several times in both directions so that the taper roller bearings can settle Fit special tool dial gauge holder VW 387 with dial gauge in such a way that a right angle is formed between the dial gauge axis and the special tool gauge plunger VW 388 10 Turn the ring gear as far as it will go via the clamping screw on the special tool adjustment device VW 521/4 and set the dial gauge to zero 11 Turn the ring gear back and read off the circumferential backlash 12 This measurement should be performed a further three times The ring gear must be turned 90° before every measurement The difference between the four measurements must not exceed 0.03 mm Furthermore, none of the measurements may deviate by more than 0.04 mm from the circumferential backlash noted on the ring gear If any one of the specified dimensions is not correct, the adjusting shims S1 and S2 must be replaced again Note! The total shim thickness S1 + S2 must not be changed Page 3.10 Drivetrain Repair – Sports Cars 6-Speed 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 6-Speed 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 4.1 Conversion Charts Notes: Page 4.2 Drivetrain Repair – Sports Cars 6-Speed Part Number - PNA P30 G01 ... Charts Drivetrain Repair – Sports Cars 6-Speed Drivetrain Repair – Sports Cars 6-Speed Transmission Type Designations Transmission Number... World-Wide 911 GT3 (997) - USA/Canada Drivetrain Repair – Sports Cars 6-Speed Page 1.5 Transmission Type Designations Page 1.6 Drivetrain Repair – Sports Cars 6-Speed 911 (996)/Boxster S (986)... 15 Drivetrain Repair – Sports Cars 6-Speed Page 2.1 911 (996)/Boxster S (986) Transmission Notes: Page 2.2 Drivetrain Repair – Sports Cars 6-Speed 911 (996)/Boxster