Workshop Manual ail Carrara Ff Dr. Ing. h.c. F. Porsche Aktiengesellschaft‘The workshop manual is only for the internal use of the Porsche Dealer Organization. © 1988 Dr. Ing. h.c. F. Porsche Aktiongesellschatt Technical Service Department D-7140 Ludwigsburg All rights reserved — Printed in Germany WKD 482520List of Repair Groups Carrera 4 General Repair Groups Volume 1 Engine, Maintenance Technical Data Maintenance, Self-diagnosis Engine, Crankcase, Suspension Engine, Crankshaft, Pistons Engine, Cylinder Head and Valve Drive Engine, Lubrication Engine, Cooling Fuel Supply Fuel System, Electronic Injection Exhaust System/Emission Controls Starter, Power Supply, Cruise Control Ignition System Diagnosis Volume Il Transmission (manual) Clutch, Controls Clutch Manual Transmission, Controls, Case Manual Transmission, Gears, Shafts Differential, Transaxle System, All-Wheel Drive Diagnosis Volume Ill Transmission (automatic) Clutch, Controls Torque Converter Automatic Transmission, Controls, Case Automatic Transmission, Gears, Shafts Differential, Transaxle System Diagnosis Volume IV Chassis Front Wheel Suspension Rear Wheel Suspension, Axle Shaft Wheels, Tires, Alignment Antiblock System Brakes, Mechanical Brakes, Hydraulics, Regulator, Booster Steering Diagnosis BASSRTS| SBSKS!] SREKS Volume Vi Body Body-Front Section Body-Center Section Body-Rear Section Lids Doors Electric Sunroof Hardtop Bumpers Glasses, Window Control Exterior Equipment Interior Equipment Seats Seat Covers RUBBLSVSIRSlLS Volume VI Heating, Ventilation, Air Condition Electrics Heater Ventilation Air Conditioner Diagnosis Instruments, Fuel Gauge, Alarm System Radio, Telephone, On-board-computer Windshield Wipers and Washer Exterior Lights, Lamps, Switches Interior Lights Diagnosis SES28 SRB Volume VII Electrics Wiring Diagrams Wiring s 8 Printed in Germany, 1988911 Carrera 2 Table of contents volume Ill Page Clutch, autom., torque converter Technicaldata............-2.00- Removing and installing the torque converter . 32-0101 32-101 Automatic transmission, controls, case Removing and installing the position switch on transmission . 37-101 Adjusting cable for selectordevice ........... . 37-102a Removing and installing cable for selector mechanism . . 37-102 Removing and installing selector mechanism... . . . . 37-1029 Dismantling and assembling selector mechanism wae . 37-1021 Dismantling and assembling gear selecting system with keylock and shittiock oe . 37-102m Removing and installing lift solenoid tor shiftlock . 37-102q Removing and installing keyolock bowden cable . . . . 37-102s Checking keylock and shiftlock ........ . 37-102u Removing and installing rear transmission case » 37-103 Removing and installing the intermediate plate . 37-107 Dismantling and assembling intermediate plate . . . . . 37-110a Disassembling and assembling the parking lock . . . oe oe oe » 37-411 Dismantling and assembling transmission... ... . a aaa aoe . 37-115 * Dismantling and assembling transmission. ..............-.0-000000- 37-123 Automatic transmission, gears, shafts Checking the ATF fluidlevel ............., Bo Ee . 38-101 Changing ATF fluid and cleaning the ATF strainer . . . 38-103 Flushing ATF cooler andlines ........ . 38-104a Removing and installing ATF cooler ; . 38-104c Removing and installing the inductive speed sensor + 38-105 Removing and installing the wiring harness for the transmission - 38-107 Removing and installing the hydraulic control unit. . +. 38-109 Removing and installing solenoid valves. ..... . . +. 88-113 Removing and installing the rotary shaft seal for the ATF pump -. 98-417 Removing and installing the ATF pump . 38-119 * No provisions are currently made for repair of the automatic section. Table of contents 101 Printed in Germany — XXI, 1994volume Table of contents 911 Carrera 2 * Dismantling and assembling 4th gear tower 2.0... eee eee * Dismantling and assembling output shaft and freewheel . . . * Dismantling and assembling clutch E * Dismantling and assembling brake F * Dismantling and assembling brake pack CD with spider shaft * Dismantling and assembling spider shaft . * Dismantiing and assembling brake ©, C’ and D * Dismantling and assembling clutch B. . . . * Dismantling and assembling clutch A . . . * Determining the end clearance Dfferential Disassembling and assembling the long joint flange ..... . 39-101 Removing and installing the rotary shaft seal for the short joint flange 39 - 105 Sealing of the driving shaft 39 - 107 Removing and installing diferential and drive pinion... .. 2... 39 - 109 Dismantling and assembling differential. . . 39 - 115 Dismantling and assembling drive pinion . . . . 39-119 Adjusting drive set... 0... e eee eee eee 39 - 123 Diagnosis Tiptronic Diagnosis / Troubleshooting Diagnosis Tiptronic... 2.2. eee : 037/38 - 101 Troubleshooting mechanical / hydraulic section... 0.2.0.0... eee eee D38 - 101 * No provisions are currently made for repair of the automatic section. 102 Table of contents Printed in Germany - XX, 1995911 Carrera 2 General Technical data 4-speed Tiptronic transmission ASO Equipment Installed in Type Identification code Model year A50/01 4-speed 911 Carrera2 90 worldwide Technical data oto1 Printed In Germany - VI, 1990911 Carrera 2 General Technical data General data ‘A50/01 Design fully-automatic 4-speed planetary transmission (Tiptronic) Ratio Spur pinion 1.100 4st gear 2.479 2nd gear 1.479 3rd gear 1.000 4th gear 0.728 Reverse gear 2.086 Final drive Hypoid bevel gear with 15 mm offset — Final drive ratio 9:33 i = 3.667 Stall speed 2300 200 Capacity, rear axle final drive approx. 0.9 | multi-grade transmission oil 75 W 90 API classification GL5 (MILL 2105 B), optionally SAE 90 Capacity, automatic unit with converter Total capacity approx. 9.0 1 Change quantity approx. 3.0 | ATF-Dexron Il D Technical data Printed In Germany ~ VI, 1990 0103911 Carrera 2 Clutch, autom., torque converter Technical data 4-speed Tiptronic transmission A50 32 wor Type Identitication code Equipment —_ installed in Model year AS50/01 4-speed 911 Carrera 2 90/91 worldwide A50/02 4-speed 911Carrera2 92/93/94 worldwide (except USA) A50/03, 4-speed 911Carera2 92/93/94 USA Technical data 32-0101 Printed in Germany ~ X00, 1994911 Carrera 2 Technical data Clutch, autom., torque converter 32 General data ‘A5O/O1 ‘ABO/O2 ‘50/03 Design fully-automatic 4-speed planetary transmission (Tiptronic) Ratio Spur pinion 1.100 1st gear 2.479 2nd gear 1.479 3rd gear 4.000 4th gear 0.728 Reverse gear 2.086 Final drive Hypoid bevel gear with 15 mm offset Final drive ratio 9:33 i = 3.667 9:32 Stall speed 2300 - 400 Capacity, rear axle final drive approx. 0.9 | mutti-grade transmission oll 75 W 90 API classification GLS (MIL-L 2105 B), optionally SAE 90 Capacity, automatic unit with converter Total capacity approx. 9.5 | Change quantity approx. 3.5 | ATF-Dexron II D Technical data Printed in Germany - XXil, 1904 32 - 0103911 Carrera 2 Clutch, autom. torque converter 32 Removing and installing the torque converter Removing 1. Remove transmission. 2, Remove converter, with transmission in hori- zontal position. Note Do not damage converter bearing assembly and rotary shaft seal. Installing Carefully insert converter, with transmission in horizontal position. Turn the converter to and fro until the gear toothing engages and the installation position is reached. ase A = approx. 25 mm 2. Secure converter against falling out with special tool 9325 Removing and installing the torque converter Printed in Germany ~ Vi, 1990 32-101911 Carrera 2 Automatic transmission, controls, case 37 Removing and installing the position switch on transmission Removing 5. Unlock cable holder, remove plug-in connec- 1. Move selector lever to position “N’. glon/and/ disconect: 2. Remove transmission underbody cladding. 3. Disconnect selector lever cord pull at actuating lever. 4. Remove actuating lever. 6. Unscrew fixing screws for position switch and remove switch. Installing Installation takes place in reverse order. aerate Tightening torques: A = Selector lever cord pull B = Actuating lever Position switch to transmission = 10 Nm C = Hexagon nut ( M8 x 1) with washer Actuating lever to switching shaft = 15 Nm D = Fixing screws Removing and installing the position switch on transmission 37-101 Printed in Germany ~ Vil, 199037 Automatic Transmission, Controls, Case 911 Carrera 2 1. Set selector shaft to position "N" (turn shaft 2. Check, and if necessary adjust, setting of anti-clockwise up to the stop and then back selector lever cable. two clicks) and place switch in the correct position. 10497 2. Adjusting multifunctional switch. — Push pointer of special tool 9326 onto the selector shaft and turn the switch until the locating pin can be pushed into the fixing hole of the switch. Tighten the mounting screws to 10 Nm (7 ftlb.) in this position. A= locating pin 37 - 102 Removing and installing multifunctional switch on transmission Printed in Germany - XXIl, 1994911 Carrera 2 Automatic transmission, controls, case 37 Adjusting cable for selector device . Move selector lever to position “1". p Move multi-function switch to position “1” by pushing forward operating lever on switch by maximum amount. s Push cable forward and adjust position of fork head until bore holes of fork head and operating lever on gearbox lie exactly one over the other. From this posttion rotate fork head a further two tums onto thread of cable. > Check adjustment by shifting through all the gears and confirming that gear is displayed on speedometer. In addition change gate from "D" to “M”. This must be possible with ‘one smooth, straightline movement. Adjusting cable for selector device Printed in Germany ~ Vil, 1990 37 - 102aion, controls, case 37 911 Carrera 2 Removing and installing cable for selector mechanism Removing and installing cable for selector mechanism 37 - 1026 Printed in Germany ~ Vil, 199037 Automatic transmission, controls, case 911 Carrera 2 Removing and installing cable for selector mechanism 37 - 102d Removing and installing cable for selector mechanism Printed in Germany ~ Vil, 1990911 Carrera 2 Automatic transmission, controls, case 37 Note: [ Installation No. | Designation Qty. | Removal 1 | Fork head 1 2 | Hexagon nut 1 3. | Gaiter seal 1 4 | Guide tube 1 5 | Fork head 1 6 | Hexagon nut 1 7 | Gaiter seal 1 8 | Guide tube 1 9 | Washer 1 10 | Rubber mount 1 11. | Spacer tube 1 12 Rubber mount 1 13 | Washer 1 | 14 | Cable Screw on to half length of thread on cable Tighten to 6 Nm (4.4 ftlb) Tighten to 6 Nm (4.4 ftlb) Install in correct position Install in correct position Readjust Removing and installing cable for selector mechanism Printed in Germany ~ Vil, 1990 37 - 102e37 Automatic transmission, controls, case 911 Carrera 2 Instructions for removal and installation Removal 4, Disconnect cable on selector lever casing 1. Remove underfloor paneling for gearbox and disconnect guide tube. veling. and center underfloor paneling, oe 2. Disconnect cable on operating lever and re- 1. Installation is carried out in reverse order. move fork head. 2. Adjust cable for selector mechanism (see P. 37 - 102a). sisr A = Fork head 3. Disconnect guide tube on bracket west 37 - 102t Removing and installing cable for selector mechanism Printed In Germany ~ Vil, 1990911 Carrera 2 Automatic Transmission - Operation, Housing 37 Removing and installing gear selecting system Removal 1. Disconnect battery. 2. Remove center underside panel 3. Disengage selector lever cable from deflec- tion lever and undo guide tube. 1086-97 4. Unscrew release button and pull off selector knob. 5. Remove center console. 6. Disconnect cable valve body from switch plate (only for keylock models) 7. Disconnect connectors for switch plate. 8. Unscrew four mounting screws (M 6) and take out selector lever operator from above. Installation Tightening torques: Gear selecting system to body = 10 Nm (7 filb) Cable valve body to switch plate = 2,5 Nm (2 ftlb) 1. Install in reverse order. 2. Press selector knob manually until it is up against the stop, making sure the twist lock engages in the cutout in the selector lever. 3. Check release button for smooth operation. It must return into the home position by itself. 4, Check selector lever cable adjustment and readjust if required. 5. Check operation of keylock and shiftlock (if fitted). Removing and installing gear selecting system Printed in Germany - XV, 1992 37 - 102g911 Carrera 2 Automatic transmission, controls, case 37 Dismantling and assembling selector mechanism Dismantling and assembling selector mechanism 37 - 102i Printed in Germany — Vil, 199037 Automatic transmission, controls, case 911 Carrera 2 Dismantling and assembling selector mechanism @e—1 4007 37 - 102) Dismantling and assembling selector mechanism Printed In Germany ~ Vil, 1990911 Carrera 2 Automatic transmission, controls, case 37 Note: No. | Designation Qty. | Removal | Installation 1 | Unlocking button 1 | Unscrew by hand Must return automatically to original position after operation 2. | Selector lever handle 1 | Pull off by hand Press on in correct posi- tion until properly in con- tact. Twisting lock must engage with lock on shift lever. 3. | Cover panel 1. | Can only be taken out | from below and with cen- | ter console removed 4 | Cover } 1 5 | Hexagon screw loa Tighten to 10 Nm (7.3 ftlb) 6 | Washer | 4 7 | Seal 1 8 | Hexagon nut 2 Tighten to 2 Nm (1.4 fib) 9 | Flat-head screw 2 10. | Control plate 1 11 | Clamping screw 1 Tighten to 23 Nm (169 fib) 12 | Reversing shaft 1 13. | Rubber mount 1 14 | Selector lever (complete) 1 15. | Lock | | 16 | Gate 1 Must engage in recess in control plate | 17. | Selector lever casing 1 Note Coat all sliding surfaces in low-temperature grease (e.g. Shell $ 6508) Dismantling and assembling selector mechanism 37 - 102k Printed in Germany ~ Vil, 1990911 Carrera 2 Automatic Transmission, Operation, Housing 37 Dismantling and assembling gear selecting system with keylock and shiftlock Tools No. | Designation Special tool | Order number | Explanation | Assembly mandrel 9542 | 000.724 954.20 Dismantling and assembling gear selecting system with keylock and shiftlock 37 - 102m Printed in Germany - XV, 199237 Automatic Transmission, Operation, Housing 911 Carrera 2 Dismantling and assembling gear selecting system with keylock and shiftlock 37 - 102n Dismantling and assembling gear selecting system with keylock and shiftlock Printed in Germany - XV, 1992911 Carrera 2 Automatic Transmission - Operation, Housing 37 Note: No. | Designation Qty. | Removal | Installation 1 | Release button 1 | Screw off manually Must return to home position automatically | after it has been | actuated 2 | Selector knob 1 | Pull off manually Push up to stop in correct position. Twist lock must engage in | | cutout in selector lever 3. | Shroud | 1 | Can only be removed | | | from below with the center | | console removed 4 | Cover 1 5 | Hexagon head screw 2 Tighten to 2.5 Nm (2 ftlb) 6 | Sleeve 2 | 7 | Switch plate 1 8 | Plug 1 9 | Tensioning sleeve 1 | Drive out using Special | Bore of driver and relay Tool 9542 shaft must match 10 | Deflection lever fa 11. | Seal fo4 12. | Rubber mount ja 13. | Selector lever 1 | Shift into manual speed | selection gate 14. | Driver ,o4 15._| Hex socket head bolt | 2 Tighten to 6.6 Nm 16 | Shift-Lock leat | 17 | Plug feed 18 | Cover Jo4 19 | Gasket ea 20 | Housing | 1 Note Coat all sliding surfaces with low-temperature grease (e.g. Shell S 6508) Dismantling and assembling gear selecting system with keylock and shiftlock 37 - 1020 Printed in Germany - XV, 1992911 Carrera 2 Automatic Transmission - Operation, Housing 37 Removing and installing lift solenoid for shiftlock Note When checking the lift solenoid electrically, be sure to observe correct polarity Terminal 1 = Positive Terminal 2 = Negative Removal 1. Remove center console and gear selecting ‘system. 2. Remove switch plate. 3. Using a suitable tool, press connecting rod carefully off the lift solenoid 4. Using sleeves and hexagon head bolts, fit lift solenoid to gate in such a manner that it remains free to slide in an axial direction. eo Adjusting the lift solenoid: Set selector lever to position ,P*. — Slide lift solenoid all the way back in the slots of the gate. = Push iron core from the lift solenoid towards the paw! until it contacts the stop and locate it in this position. - Slide the actuated lift solenoid axially until the idler contacts the stop of the paw. Tighten hexagon head bolt to 2.5 Nm 67 2 1 ee) teas ORF KS. aa O° > — et 4, Screw out mounting screws and take off lift 9 a solenoid. | 5 : le Installation 1. Set selector lever to "1" position. . iacaeeel beeen ci 1- Hexagon head bolt —2 - Sleeve. . : 3 - Lift solenoid 4- Iron core 3. Clip connecting rod to lift solenoid, retaining 5 - Connecting rod chow the connecting rod in correct position using Miele a suitable wire hook or marking tool and : pushing the free lift solenoid carefully into B heey ope on or emo the ball socket Removing and installing lift solenoid for shiftlock 37 - 102q Printed in Germany - XV, 1992911 Carrera 2 Automatic Transmission - Operation, Housing 37 Removing and installing keylock bowden cable Removal 1. Disconnect battery. 2. Remove complete center console, knee guard and side nozzle. 3. Undo Central Information System and leave it supended on the wiring 4, Turn ignition lock to position ,2" (Ignition on). Note The ignition lock must be in position ,2'. If it is left in any other position, both the lock and the bowden cable may be damaged. 5. Unbolt bowden cable from ignition lock. 0807 6. Undo mounting screws of valve body. 7. Disengage bowden cable from pedal floor- board and from bracket for center console. Installation 1. Assemble in reverse order, observing the following points. 2. Turn ignition lock to position ,2" (Ignition on) and fit owden cable to ignition lock. Tightening torque: 2.5 Nm (2 ftlb) 3. Fit bowden cable valve body using sleeves and hexagon head bolts. Tightening torque: 2.5 Nm (2 ftlb) 4, Set selector lever to position ,P* and tun ig- nition lock to position ,0". Note If the ignition lock cannot be turned to the 0 position, the bowden cable must be re- adjusted. Removing and installing keylock bowden cable Printed in Germany - XV, 1992 37 - 102s37 Automatic Transmis ion - Operation, Housing 911 Carrera 2 5. Adjust bowden cable, turning the cable sleeve on the valve body until the lock slide reaches a setting of 2 + 0.5 mm (refer to Fig.). soo.s7 A=2+05mm 6. Check operation of keylock and shiftlock 37 - 102t Removing and installing keylock bowden cable Printed in Germany ~ XV, 1992911 Carrera 2 Automatic Transmission - Operation, Housing 37 Checking keylock and shiftlock Checking the keylock (ignition key lock) Selector lever position| Position Keylock Ignition key of release button operation Pp not actuated no rotary, may be pulled off P actuated yes cannot be turned to pulloff position RND3.2-4 not actuated yes cannot be turned to pulloff actuated Position Checking the keylock (selector lever lock) Ignition key Release button Keylock Selector lever position status operation Pulled off or locked yes locked pulled position | Position not no not 1or2 | locked locked Checking the shiftlock Selector lever position; Ignition Shiftlock Brakes Selector lever operation P-R-N-D-3-2-4 off no actuated not locked | not actuated PandN on yes not actuated | locked PandN on yes actuated | not locked Checking keylock and shiftlock 37 - 102u Printed in Germany ~ XV, 1992911 Carrera 2 Automatic transmission, controls, case 37 Removing and installing rear transmission case Tools fe @ AX a 9 oe No. | Designation Specialtoo! | Order number | Explanation 1 Transmission holder 9324 000.721.932.40 = Holding device 9325 000.721.932.50 3 | socket key insert 9330 000.721.933.00 Removing and installing rear transmission case 37-103 Printed in Germany — XV, 199237 Automatic transmission, controls, case 911 Carrera 2 Removing and installing rear transmission case 37 - 104 Removing and installing rear transmission case Printed in Germany ~ Vi, 199037 911 Carrera 2 Automatic transmission, controls, case Note: No. | Designation Qty. | Removal Installation (= ftlb) 1 | Fillister head screw 4 | Use Special Tool 9330 to | Tighten witht 23 Nm (17) remove 2 | Joint flange 1 3 | O-ring 1 Replace, oil slightly 4. | Screw plug 3 Tighten with 50 Nm (36) 5 | Sealing ring 3 Replace 6 ter head screw 3 | Remove with Torx insert Tighten with 46 Nm (34) 50 7 | Fillister head screw 3 | Remove with Torx insert | Tighten with 46 Nm (34) 150 8 | Fillister head screw 6 | Remove with Torx insert | Tighten with 46 Nm (34) T50 9 | Rear transmission case 1 10 | Protective tube 1 Large diameter to final drive 11 | Seal 1 Replace, glue to case with a small quantity of grease (vaseline) 12. | Shim X | Note thickness for re- Redertermine thickness if installation required (refer to page 38 - 171) 13 | Needle cage 1 14 | Angle ring 1 Fit in correct position 15 | Automatic transmission 1 Pay attention to installa- tion position of clutch A. Make sure that the square drive shaft rings are correctly fitted. Coat the drive shaft with a ‘small quantity of grease in the area of the square rings. * Must be checked and, if required, corrected after each transmission installation. Removing and Installing rear transmission case Printed in Germany ~ 200, 1994 37-10537 Automatic transmission, controls, case 911 Carrera 2 Assembly instructions for removal and installation Removal Installation 1. Remove the transmission and torque con- 1. Check the installation position of clutch A. verter. The installation depth has been reached when the distance “C” Is approx. 8.5 mm. 2. Secure transmission on assembly block with holding device 9324. asx A=ClutchA B = Square rings C = Installation depths 37-106 Removing and Installing rear transmission case Printed in Germany - XX, 1996911 Carrera 2 Automatic transmission, controls, case 37 Removing and installing the intermediate plate Removing and installing the intermediate plate 37 - 107 Printed in Germany ~ Vi, 19903 7 Automatic transmission, controls, case 911 Carrera 2 Removing and installing the intermediate plate 37 - 108 Removing and installing the Intermediate plate Printed in Germany — XV, 1992914 Carrera 2 Automatic transmission, controls, case 37 Note: T No. | Designation Qty. | Removal Installation 1 | Hexagon screws 1 Tighten with 46 Nm 2 | Washer 1 3 | Fillister head screw "1 Tighten with 23 Nm 4 | Fillister head screw 6 Tighten with 23 Nm 5. | Front transmission cover* 1 6 | Seal 1 Replace 7 | O-Ring 1 Replace, oil with ATF 8 | Shim X | Note thickness for reinstal- lation 9 | Gear wheel with tapered- 1 | Note correct position for | Adjust preload if required roller bearings* reinstallation | 10 | Gear wheel with bearing 1 | Note correct position for | Set by the manufacturer. assembly* reinstallation 11 | Fillister head screw 2 Tighten with 23 Nm 12. | Intermediate plate” 1 13 | Seal 1) Replace 14. | Protective tube 1 Large diameter to final drive 15 | Tapper rolier bearing 1 | Remove with intemal pul- | Heat transmission cover | outer race ler (e.g. Schrem to approx. 120 deg. C 60 - 70) and press in to stop 16 | Adjusting shim X | Record thickness for rein- | Redetermine thickness if stallation required | 17. | Automatic transmission 1 with final drive Note ‘The spur gear drive is only available as a complete set (intermediate plate, transmission cover and adjusted spur gears). No adjustment of the preload of the taper roller bearings is therefore required. Removing and installing the intermediate plate 37 - 109 Printed in Germany - XXHl, 1994911 Carrera 2 Automatic Transmission - Operation, Housing 37 Dismantling and assembling intermediate plate Tools T No. | Designation Special tool Order number | Explanation Retaining device |000.721.934.00 Dismantling and assembling intermediate plate 37 - 1108 Printed in Germany - XV, 199237 Automatic Transmission - Operation, Housing 911 Carrera 2 Dismantling and assembling intermediate plate 37 = 110b Dismantling and assembling intermediate plate Printed in Germany ~ XV, 1992911 Carrera 2 Automatic Transmission - Operation, Housing 37 Note: No. | Designation Removal Installation 1 | Snap ring 2 | Bearing cover Grab at lugs to lift out 3 | Round seal Replace, coat with ATF fluid 4 | Shaft seal Fitting depth 2.0 0.5 mm 5 | Lock nut Fit Special Tool 9340 into | Tighten to 260 Nm vise. (184 fib). Put intermediate plate into | Lock by upsetting the position and undo nut. flange (2 x 180°) 6 | Helical gear Press out using a hy- draulic press. 7 | Adjuster ring* Record thickness for Thickness can only be reassembly determined by manu- facturer 8 | Inner race of taper roller Mark for reassembly Heat to approx. 120°C bearing* and press on 9 | Bearing cover * 10 | Round seal Replace, coat with ATF fluid 11 | Inner race of taper roller Remove across assembly | Heat to approx. 120°C bearing* bore of helical gear. Mark | and press into place for reassembly. 12 | Outer race of taper roller Heat intermediate plate tol bearing approx. 120°C and press into place 13 | Breather cover Lever off 14 | Breather tube Pull out Press in to stop 15. | Intermediate plate Note The parts identified by an * have been preadiusted by the manufacturer. Dismantling and assembling intermediate plate Printed in Germany - XXi, 1994 37 - 110e911 Carrera 2 Automatic transmission, controls, case 37 Disassembling and assembling the parking lock Disassembling and assembling the parking lock 37-411 Printed in Germany - VI, 199037 Automatic transmission, controls, case 911 Carrera 2 Disassembling and assembling the parking lock 37-112 Disassembling and assembling the parking lock Printed in Germany ~ VI, 1990911 Carrera 2 Automatic transmission, controls, case 37 Note: ] No. | Designation Qty. | Removal Installation 1 | Bushing 1 2 | Fillister head screw 1 | Remove with Torx insert | Tighten with 10 Nm Taz 3 | Guide plate 1 4 | Guide piece 1 5 Catch 1 | 6 | Spring 1| Insert in correct position 7 | Pin 1 8 | Circlip 1 9 | Parking lock wheel } 4 Make sure that the square ring is correctly seated 10 | Clamping pin 1 11 | Protective cap 1 | Drive out to the outside by | Replace gentle blows on shaft No. 14 12. | Circlip 1 13. | Shim ring 1 14 | Shaft 1 | Mark installation position | Insert in correct position 18 | Notched disk 1 | 16 | Rotary shaft seal 1 | With transmission in built in condition, remove posi- tion switch and carefully lever out with a suitable screwdriver Wind plastic insulating tape around the shaft toothing as an assembly aid, slightly oil sealing lip and press in flush Disassembling and assembling the parking lock Printed in Germany ~ Vi, 1990 37-11337 Automatic transmission, controls, case 911 Carrera 2 Work instructions for disassembling and assembling Disassembling 2. Insert spring for catch in correct position. 1. Remove transmission. 2. Remove intermediate plate. Note Part Nos. 11 to 15 can be removed only when the rear transmission case and the ATF pan have been dismantled. Assembly 1. Replace O-ring on output shatt. oss7 37-114 Disassembling and assembling the parking lock Printed in Germany ~ VI, 1990911 Carrera 2 Automatic Transmission - Operation, Housing 37 Dismantling and assembling transmission No. | Designation Special tool Order number | Explanation Removal handle | 9327 (000.721.932.70 | Dismantling and assembling transmission Printed in Germany ~ XV, 1982 37-11537 Automatic Transmission - Operation, Housing 911 Carrera 2 Dismantling and assembling transmission s—t 37-116 Dismantling and assembling transmission Printed in Germany ~ XV, 1992941 Carrera 2 Automatic Transmission - Operation, Housing 37 No. oan an W 12 13 14 15 16 7 18 19 20 21 22 23 “Note: Designation Qty. | Removal Installation Plug 1 Tighten to 40 Nm (29 fib) Seal 1 Replace Banjo bolt 1 Tighten to 40 Nm (29 ftlb) Seal 2 Replace Hexagon head bolt | 6 Tighten to 6 Nm (4 ftlb) Bracket (straight leg) 2 Short legs must force on 0 the ATF pan | Bracket (curved leg) i 4 Short legs must force on { the ATF pan | ATF pan , 4 Gasket } 4 Magnet \ 2 Place into grooves in| | ATF pan Pan head screw | 3 Tighten to 8 Nm (6 fb) (M6 x 65) ATF strainer | 1 | Round seal )o4 Replace Hexagon nut ; 4 Tighten to 12 Nm (9 ftlb) Pan head screw | 14 Observe correct length, | tighten to 8 Nm (6 ftlb) | ‘Spring washer {1 Bracket }o4 Inductive rpm pickup ia | Hydraulic control unit with | 4 The straight surface on wiring harness | the harness socket must i point towards the outside Round seal bg Replace | Pan head screw | "1 Observe correct length, | tighten to 8 Nm (6 fb) | | Adapter | 4 | | Snap ting 7 | Dismantling and assembling transmission Printed in Germany ~ XV, 1992 37-11737 Automatic Transmission - Operation, Housing 911 Carrera 2 Note: ] No. | Designation Qty. | Removal _ Installation 24 | Thrust spring (short) 4 25 | Thrust spring (long) 3 26 | Sealing sleeve 6 | Pull out with Press in to stop using a | Special Too! 9927 suitable mandrel 27 | Sealing sleeve 1 | Pull out with Press in to stop, observ- | Special Tool 9327 ing correct position 28 | Sealing nut 1 Tighten to 30 Nm (22 ftb)} 29 | Seal 1 Replace 30 | Banjo bolt 1 Tighten to 40 Nm (29 ftlb) 31 | Seal 2 Replace 32 | Flange 1 33. | Ball (6 mm dia.) 1 34 | Countersunk screw 2 Tighten to 5 Nm (4 ftlb) 35. | ATF indicator tube 1 | 36 | Sealing ring 1 Replace 37 | Hose clamp | 2 38 | Flange 1 39 | Hose ho4 40 | Transmission case e-4] | 37-118 Dismantling and assembling transmission Printed in Germany - XV, 1992911 Carrera 2 Automatic Transmission - Operation, Housing 37 Dismantling and assembly notes Dismantling . Remove and install rear transmission case (page 37 - 103). y Remove and install intermediate plate (page 37 - 107) 2 Remove and install parking lock (page 37 - 111). - Drain ATF fluid. a Unscrew 13 mounting screws (head dia. 12 mm) for hydraulic control unit and lift off control unit. 6. Pull sealing sleeves out of the bores, using Special Tool 9327. Assembly 1. Using a suitable mandrel, press sealing sleeves into the bores of the transmission case. Make sure the sleeves are not tilted or damaged. Dismantling and assembling transmission Printed in Germany - XV, 1992 soar A ~ short sealing sleeves B — bevelled sealing sleeve for lubrication pressure feed 37-11937 Automatic Transmission - Operation, Housing 911 Carrera 2 2. Installation position of the bevelled sealing sleeve for lubrication pressure feed A - Sealing sleeve 3, Place thrust springs into position and locate with snap rings A - Long thrust springs B - Short thrust springs 4. Fit wiring harness to transmission case (straight surface on socket points to out- side), place control unit into position and tighten all mounting screws lightly. A = Screw length = 80 mm B = Screw length = 65 mm C = Screwlength = 105mm D = Screw length = 60 mm 5. Put control unit into position, placing detent disk into position 1 (1st gear) and pushing control unit back until it contacts the detent disk. Keeping the unit in this position, tighten mounting screws to 8 Nm. A- Detent disc B - Selector valve 37 - 120 Dismantling and assembling transmission Printed in Germany ~ XV, 1992911 Carrera 2 Automatic Transmission - Operation, Housing 37 2 Place inductive rpm pickup into position and fit retainer plate in such a manner that the lugs engage into the grooves of the connec- tor. 90.38 Dismantling and assembling transmission 37-121 Printed in Germany ~ XV, 1992911 Carrera 2 Dismantling and assembling transmission Automatic Transmission - Operation, Housing 37 wns No. | Designation Special tool | Order number | Explanation 1 Assembly sleeve 9331 000.721.933.10 2 Puller hook 9328/1 000.721.932.81 3 Retaining device 9329/1 000.721.932.91 4 Clamp 9334 000.721.933.40 Dismantling and assembling transmission 37-123 Printed in Germany ~ XV, 199237 Automatic Transmission - Operation, Housing 911 Carrera 2 Dismantling and assembling transmission 37-124 Dismantling and assembling transmission Printed in Germany ~ XV, 1992911 Carrera 2 Automatic Transmission - Operation, Housing 37 ~ ] Note: No. | Designation Qty. | Removal Installation 7 T 1. | Adjusting shim X | Record thickness for Check shim thickness reassembly Whenever the transmis- | sion has been dismantled | and redetermine correct | thickness as required | (refer to page 38 - 171) 2 | Axial needle roller cage 1 3 | Angled disc 1 Install in correct position 4 | Drive shaft with couplingA | 1 | For dismantling and | assembly, refer to page 38 - 168, 5 | Angled disc 1 Use grease (vaseline) to stick to drive shaft in correct position 6 | Axial needle roller cage 1 7 | Thrust washer 1 8 | Disc carrier 1 9 | Snap ring jo 40 | Support ring 1 | 11. | Round seal 1| Replace, fit with | Special Tool 9331 12 | Clutch B 1 | Pull out using Special Check rectangular ring Tool 9328/1. For dismant- | for correct position ling and assembly, refer | to page 38 - 161 13 | Snap ring ee | 14 | C/D pack | 1 | Lift out with Special Toot | Install with Special Tool \ 9329/1 and place on 9329/1, making sure the | Special Tool 9314. 4 oil feed bores line up | For dismantling and with the bores for the | assembly, refer to sealing sleeves | page 38 - 143 15. | Angled disc joa Use grease (vaseline) | to stick to spider shaft, | observing correct postion 16 | Axial needle roller cage | 1 | | Dismantling and assembling transmission Printed in Germany ~ XV, 1982 37-12537 Automatic Transmission - Operation, Housing 914 Carrera 2 Note: No. | Designation Qty. | Removal | Installation _ 17, | Thrust washer 1 18 | Round seal 1 Replace 19 | Countersunk screw 10 Tighten to 10 Nm (7 ftlb). (Torx bit TX 30) Observe correct tighten- ing torque, otherwise pressure losses at the clutch may resutt 20 | 4th gear tower 1 | Use Special Tool 9334 to | Insert with Special Tool | lift out 9334, making sure the | three oil feed bores of | cylinder € and trans- mission case line up with each other 21 | Transmission case Joa 37 - 126 Dismantling and assembling transmission Printed in Germany ~ XV, 1992911 Carrera 2 Automatic Transmission - Operation, Housing 37 Dismantling and assembly notes Dismantling 3. Take out entire brake pack C'/C/D using 1. Remove round seal from output shaft and Special Tool 9320/1 put Special Tool #334 into place. 2. Pull out clutch B using Special Tool 9328/1, liting clutch until a resistance is felt, press back down again and pull out in one go. aves? Dismantling and assembling transmission 37-127 Printed in Germany ~ XV, 199237 Automatic Transmission - Operation, Housing 911 Carrera 2 Assembly 1. To prevent the preassembled 4th gear tower from separating again, allow Special Tool 9334 to engage into the groove of the round seal. 3, Place axial needle roller cage, thrust washers, planetary set and sun wheel into place (refer to page 38 - 122). 4, Place brake pack C'/C/D with Special Tool 9329/1 into transmission case, making sure the 4 oil feed bores line up with the bores for the sealing sleeves. 28.07 2. Place 4th gear tower minus planetary gear set and sun wheel into housing, observing correct position. The three oll feed bores of cylinder E and transmission case must line up. eotar 37-128 Dismantling and assembling transmission Printed in Germany ~ XV, 1992911 Carrera 2 Automatic Transmission - Operation, Housing 37 o Place complete clutch assembly 8 into hous- ing and press down to stop. Slip round seal onto inner part of Special Tool 9331 up to the taper and use outer section to push it in to stop. Fit support ring and snap ring in the same way. . Place drive shaft complete with clutch A into housing and rotate cylinder A to and fro until the teeth, the disc carrier and the discs engage fully with each other. The correct position is achieved if the cylinder face protrudes by approx. 8.5 mm beyond the housing face. suas? aver A Clutch A B - Rectangular rings C - Fitting depth Dismantling and assembling transmission 37-129 Printed in Germany - XV, 1992911 Carrera 2 Checking the ATF fluid level The prescribed fluid level is extremely import- ant for perfect functioning of the automatic transmission. Preconditions for checking: - Transmission underbody cladding removed - Vehicle must be horizontal — Engine operating at idling speed — Hand brake applied = Selector lever in position “P” - ATF temperature 80°C Check ATF level at 80°C. Note The ATF capacity was increased by 0.5 |. The ATF level therefore rises and the 80°C check marks move further up on the oil level tube. Refer to imaginary and dotted lines in the close-up insert. When checking the ATF level, make sure the fluid level is between those two lines (maxi- mum level 15 mm above the 80°C MAX mark present, lowest level approx. 3 mm below the 80°C MIN mark present). Automatic transmission, gears, shafts 38 A = invalid 80°C mark The exact ATF temeprature can be deter- mined with the system tester 9288. Ht necessary, top up missing ATF fluid via the quick-fil device (also refer to page 38-103). Checking the ATF fluid level Printed in Germany - Xxil, 194 38-101911 Carrera 2 Automatic transmission, gears, shafts 38 Changing ATF fluid and cleaning the ATF strainer Capacity: approx. 9.5 | Fill with ATF fluid: Change quantity: approx. 3.5 | First, fll ATF fluid up to the 30°C max. mark Oil type: via the quick-fill connection with the engine ATF-Dexron IID stationary. The ATF fluid must be changed and the ATF strainer cleaned every 40,000 km When changing the ATF fiuid, the vehicle must be horizontal and the engine switched off. Drain ATF fluid, remove ATF pan and ATF strainer (refer to page 38-109). Thoroughly clean the strainer and pan. Fit the ATF strainer with a new O-ring. Tighten the fixing screws with 8 Nm (6 fttb). Fit the ATF pan with seal. Tighten the fixing screws with 8 Nm (6 ftlb). sere A = Hexagon cap nut (tightening torque 30 Nm = 22 fb) B = Sealing ring (replace) C = Quick-fill connection Changing ATF fluid and cleaning the ATF strainer 38 - 103 Printed in Germany - XXII, 199438 Automatic transmission, gears, shafts 911 Carrera 2 ‘A = Quick-fill connection B = Hose from filling device Start engine in selector lever position “P” and allow to run at idle speed. Observe the ATF level in the oil level pipe and top up to the 30°C max. marking immediately if required. Note The ATF level in the transmission changes with the fluid temperature. Drive the transmission warm and check the ATF fluid at 80° C. Be sure to observe the note on page 38-101. Here, the fluid level must be between the 80°C min. and max. marks. The exact ATF temperature can be deter- mined with the system tester 9288. 38 - 104 Changing ATF fluid and cleaning the ATF strainer Printed In Germany - XXIl, 1994911 Carrera 2 Automatic transmission, gears, shafts Flushing ATF cooler and lines Information If the ATF is carbonized, or if there is sludge or evidence of lining abrasion in the ATF sump, it is not sufficient merely to repair or re- place the gearbox; the ATF cooler and line ‘system must be flushed with ATF. Attach additional hose of ATF filling device (see Workshop Manual Group 3/4) to ATF line with conventional twin connecting piece and flush out cooler and line system using filing device. A = Twin connecting piece M 16 x 1.5 with conical seal B = Additional hose 38 Flushing ATF cooler and lines Printed in Germany ~ Vil, 1990 38 - 104a911 Carrera 2 Automatic transmission, gears, shafts 38 Removing and installing ATF cooler Removing and installing ATF cooler 38 - 104¢ Printed in Germany - Vil, 1990911 Carrera 2 Automatic transmission, gears, shafts 38 Designation Qty. | Removal Note: | Installation oo no Bracket } | Washer-and-screw assembly Air deflector Hexagon screw Washer ATF cooler Tighten to 10 Nm (7.3 fib) Removing and installing ATF cooler Printed in Germany - Vil, 1990 38 - 104e38 Automatic transmission, gears, shafts 911 Carrera 2 Removing and installing ATF cooler Information The ATF cooler is located in the wheel house in front of the front right-hand wheel. It is at- tached to the engine oil cooler and is venti- lated by the engine oll cooler's two-stage elec- tric blower. Removal 1. Remove front wheel house liner and lower panel 2. Disconnect ATF lines and seal with suitable plugs. 3. Unfasten retaining bracket on headlamp housing. 4, Remove bracket, undoing three self-locking hexagon nuts (M8) on the wheel arch and ‘one (M6) for the diagonal brace. 5. Remove air deflector. 6. Remove hexagon screw and take out ATF cooler (illustration shows cooler removed) Note Do not disconnect oil lines from engine oil cooler. Cooler remains in wheel house. 38 - 104f Removing and installing ATF cooler Printed In Germany ~ Vil, 1990911 Carrera 2 Automatic transmission, gears, shafts 38 7. Remove ATF lines on cooler. ane Installation ‘Tightening torques: (= ftlb) Connection ATF line = 30 Nm (22.0ftIb) Retaining bracket to headlamp housing = 23 Nm (1639 ftlb) Bracket to wheel house = 23 Nm (16.9 ftlb) Diagonal brace to bracket = 10 Nm (7.3 ftlb) ATF cooler to engine oil cooler = 10 Nm (7.3 ftlb) Bolt to ATF cooler = 10. Nm (7.3 ftlb) Retaining bracket to ATF cooler = 6Nm (4.4 fib) Retaining plate to retaining bracket = 3.Nm (2.2 ftlb) 1. Installation is carried out in reverse order. 2. Replace O-rings for ATF lines on cooler. 3. Check that rubber edging strips on fan hous- ing and bracket fit properly. 4. Check ATF level and if necessary top up. Removing and installing ATF cooler Printed in Germany ~ Vii, 1990 38 - 104g911 Carrera 2 Automatic transmission, gears, shafts 38 Removing and installing the inductive speed sensor Removing Insert the sensor and mount the holding plate 1. Remove the transmission underbody clad- So that the lugs engage in the groove on the ding and ATF pan (refer to page 38-109). connector. 2. Remove the holder for the inductive sensor and pull out sensor. 20200 A = Connector groove soot Installing Tightening torque: Holder to control unit = 8 Nm Installation takes place in reverse order. Removing and installing the inductive speed sensor 38 - 105 Printed in Germany ~ VI, 1990911 Carrera 2 Automatic transmission, gears, shafts 38 Removing and installing the wiring harness for the transmission Removing 6. Mark the push-on sleeves for re-installation 1. Remove the transmission underbody clad- and pull off from the solenoid valves. ding n Remove the position switch (refer to page 37-101). 9 Disconnect the connector from the transmis- sion socket. To do this, turn the bayonet lock to the left and disconnect the connec- ‘tor: 369.98 Installing 1. Push the push-on sleeves for the solenoid valves up to the stop. Pay attention to cable colors. A = Bayonet lock B = Hexagon nut (a/f 30) = Unscrew the hexagon nut for the transmis- sion socket with a suitable extension. a Remove the hydraulic control unit with wir- ing harness (also refer to page 38-109 ). Removing and installing the wiring harness for the transmission 38-107 Printed in Germany ~ VI, 199038 Automatic transmission, gears, shafts Solenoid valves Cable colors Solenoid valve 1 | (grey-violet) Solenoid valve 2 | (green-violet) Solenoid valve 3 | (red-violet) Pressure regulator | (blue-violet) com> 2, Route wiring harness and hang in cable clamps. 911 Carrera 2 6. Connect wiring harness with transmission socket. To do this, carefully insert the con- nector in the socket (fits only in one posi- tion) and lock by turning the bayonet lock to the right. 307280 2048 3. Place hydraulic control unit on a suitable sur- face (e.g. transmission jack) at installation height. 4. Insert the socket with new O-ring so that the flattened side faces upwards. Tighten hexagon nut with 12 Nm (9 ftlb). 5. Install hydraulic contro! unit. 38 - 108 7. Install the position switch and readjust. Removing and installing the wiring harness for the transmission Printed in Germany - Vi, 1990911 Carrera 2 Automatic transmission, gears, shafts 38 Removing and installing the hydraulic control unit Removing The transmission wiring harness remains on the transmission 1. Remove the transmission underbody clad- ding 2. Drain off ATF fluid. A = Drain screw with sealing ring 3. Remove ATF pan. To do this, unscrew hol- low screw for oil level pipe and six fixing screws. B = Hollow screw C = Fixing screws 4, Remove ATF strainer with Torx insert T 27. 39298 Removing and installing the hydraulic control unit 38 - 109 Printed in Germany ~ vi, 1990Automatic transmission, gears, shafts 911 Carrera 2 90.08 6. Unscrew 13 fixing screws (head diameter 12 mm) with Torx insert T 27 and lower control unit only so far as to guarantee that the wiring harness is not subjected to any tension. Place the control unit on a suitable surface (e.g. transmission jack) Note Do not allow the control unit to hang from the wiring harness under any circumstances. A = Screw length 80 mm B = Screw length 65 mm C = Screw length 105 mm D = Screw length 60 mm 7. Mark the push-on sleeves for re-installation and pull off from the solenoid valves. 8. Pull the wiring harness out of the holding clamps and remove the control unit. Installing Installation takes place in reverse order. 1. Tightening torques: Control unit to transmission = 8 Nm (6 ftlb) ATF strainer to control unit = 8 Nm (6 ftlb) ATF panto transmission = 6 Nm (4 ftlb) Drain screw to ATF pan =40 Nm (29 ftlb) Hollow screw to ATF pa =40 Nm (29 ftlb) 38-110 Removing and installing the hydraulic control unit Printed in Germany - XV, 1992911 Carrera 2 Automatic transmission, gears, shafts 38 2. Push on push-on sleeves for solenoid valves up to the stop. Pay attention to cable colors. 4. Screw in the fixing screws for the control unit and counter slightly. Pay attention to screw lengths. e088 Solenoidvalves | Cable colors Solenoid valve 1 | (grey-violet) Solenoid valve 2 | (green-violet) Solenoid valve 3. | (red-violet) Pressure regulator | (blue-violet) A B c D 3. Mount the control unit so that the pin of the notched disk projects into the recess of the selector slide. 290.28 A= Screw length 80 mm B= Screw length 65mm C = Screw length 115 mm D= Screw length 60 mm 5. Position control unit. To do this, move notched disk to position 1 (1st gear) and push control unit back until it rests against the notched disk. Tighten fixing screws with 8 Nm in this position, Removing and installing the hydraulic control unit Printed in Germany ~ XV, 1992 38-111A = Notched disk B = Selector slide 6. Insert inductive speed sensor and mount holding plate so that the lugs engage in the connector grooves. 7. Fit ATF strainer with O-ring. Tightening torque 8 Nm. 8, Place two magnets in the beads of the ATF pan, fit seal and secure the pan with the holding brackets so that the short legs press onto the ATF pan. Automatic transmission, gears, shafts 911 Carrera 2 Note The two holding brackets with the straight legs must be mounted at the side. 9. Screw in ATF drain screw with new sealing ring. Tightening torque 40 Nm. 10. Screw in hollow screw for oil level pipe with new sealing rings. Tightening torque 40 Nm. 11. Fill with ATF fluid (refer to page 38-103). 38-112 Removing and installing the hydraulic control unit Printed in Germany ~ Vi. 1990911 Carrera 2 Automatic transmission, gears, shafts 38 Removing and installing solenoid valves Removing and installing solenoid valves 38-113 Printed in Germany - Vi, 199038 Automatic transmission, gears, shafts 911 Carrera 2 Removing and installing solenoid valves 6 Aeees See niet eee tO. 38-114 Removing and installing solenoid valves Printed in Germany ~ Vi, 1990911 Carrera 2 Automatic transmission, gears, shafts 38 Note: No. | Designation Qty. | Removal Installation 1 | Fillister head screw 5 | Remove with Torx insert | Tighten with 5 Nm (4 ftlb) T27 2. | Housing with pressure reg- | 1 Set by the manufacturer, ulator only replace complete 3 | Fillister head screw 2 | Remove with Torx insert | Tighten with 5 Nm 127 4 | Fillister head screw 1 | Remove with Torx insert | Tighten with 5 Nm T27 5 | Holder 1 6 | Fillister head screw 1 | Remove with Torx insert | Tighten with 5 Nm T27 7. | Holding plate 1 Fit in correct position, lugs point to holder No. 5 8 | Solenoid valve 3 1. | Mark for re-installation Do not confuse with sole- noid valves Nos. 11 and 14 9 | Filister head screw 1 | Remove with Torx insert | Tighten with 5 Nm T27 10 | Holding plate 1 Fit in correct position, lugs point to housing 11. | Solenoid valve 2 1 | Mark for re-installation Do not confuse with sole- noid valves Nos. 14 and 8 12. | Fillister head screw 1 | Tighten with 5 Nm 13 | Holding plate Fit in correct position, lugs point to housing 14. | Solenoid valve 1 1 | Mark for re-installation Do not confuse with sole- noid valves | Nos, 11 and 8 15 | Hydraulic control unit 1 Removing and installing solenoid vaives 38 - 115 Printed in Germany ~ Vi, 1980911 Carrera 2 Automatic transmission, gears, shafts 38 Removing and installing the rotary shaft seal for the ATF pump Removing 1, Remove transmission and converter. 2. Lever out sealing ring with VW 681 2. Press in sealing ring with special tool 9328 as far as it will go. 2008 1098 Installing Installation takes place in reverse order. 1. Wet sealing lip with ATF. Removing and installing the rotary shaft seal for the ATF pump 38-117 Printed in Germany ~ Vi, 1990911 Carrera 2 Automatic transmission, gears, shafts 38 Removing and installing the ATF pump Removing 1, Remove transmission. 2, Remove torque converter and rear transmis- sion case. ° Unscrew fixing screws with Torx insert T27 and remove pump. To do this, screw in two screws opposite each other and carefully drive out the pump by gentle blows on the screw heads 40598 A = Installation markings B = Orting 3. Install pump with new O-ring and centering sleeve. Tighten fixing screws with 10 Nm. 4. Check pump for easy operation. It must be Possible to tum the pump by hand with special too! 9329 without it catching. Installing 1. Check bearing bush for run-in scores or damage. The pump must be replaced if there are signs of damage. 2. Oil both pump wheels with ATF fiuid and place in the housing so that both installation markings are visibly facing up. Removing and installing the ATF pump 38-119 Printed in Germany - Vi, 1990911 Carrera 2 Automatic Transmission, Gears, Controls 38 Dismantling and assembling 4th gear tower one No. | Designation ‘Special tool ‘Order number —_| Explanation 1 Clamp 9334 000.721.933.40 2| Assembly support 9314 000.721.931.40 Dismantling and assembling 4th gear tower 38-121 Printed in Germany - XV, 199238 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembling 4th gear tower 38 - 122 Dismantling and assembling 4th gear tower Printed in Germany - XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls 38 T Note: ] page 38 - 131 The specified position is achieved when cylinder E} rests against the copper No. | Designation Qty. | Removal Installation 1 | Sun whee! 1 2 | Planetary set 1 Check for correct seating of the rectangular ring. Engage into hollow gear with a slight rotary motion] 3. | Angled disc 1 Fit in correct position 4. | Axial needle roller cage 1 5. | Thrust washer 1 6 | Brake F 1 | For dismantling, refer to | Make sure rectangular | page 38 - 137 rings are located correct- | ly. Rotate them slightly to! | move them into in- | stallation position 7 | Clutch € 1 | For dismantling, refer to | Fit with a rotary motion. | | angle disc 8 | Thrust washer 1 9 | Axial needle roller cage 1 | 10 | Copper angle disc 1 | install in correct position 11 | Steel angle disc 1 | install in correct position 12 Output shaft with 1 i For dismantling, refer to freewheel | page 38 - 127 _ _| 1 Note Parts No. 1 to 5 should be fitted only after the 4th gear tower has been installed Dismantling and assembling 4th gear tower 38 - 123 Printed in Germany ~ XV, 198238 Automatic Transmission, Gears, Controls Dismantling and assembly notes Dismantling 1. Take Special Too! 9334 off the output shaft, lift the complete pack by the cylinder and place onto Special Tool 9314. A Zz J © 32238 A - Special Tool 9314 2. Take off sun wheel and planetary set. 911 Carrera 2 3, Turn over the complete pack on the out- put shaft and place on a suitable support (e.g. Special Tool! 9508/1). A Manes! A = Special Tool 9508/1 4. Take off cylinder F and E Assembly 1. Place preassembled output shaft on a suitable support (e.g. 9508/1) 2. Put steel and copper angle disc in place and fit cylinder E with a rotary motion. Note The teeth of the end disc and of the free- wheel outer ring must engage with each in such a manner that cylinder E rests on the copper angle disc. 38-124 Dismantling and assembling 4th gear tower Printed in Germany - XV, 1992911 Carrera Automatic Transmission, Gear 38 Controls 4. If the freewheel has been fitted correctly, cylinder E must be free to rotate clockwise with the output shaft being held, but it must lock when an attempt is made to rotate it counterclockwise. 6. To prevent the preassembled pack from separating, allow Special Tool 9334 to engage into the groove of the round seal. Cp assr sose A — Special Tool 9334 5. Fit axial needle roller cage and thrust Note washer. Place cylinder F onto cylinder E The teeth of end disc and freewheel with a rotary motion until it is in assembly outer ring engage only over a length of position. approx. 3 mm, eae Dismantling and assembling 4th gear tower 38 = 125 Printed in Germany ~ XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls 38 Dismantling and assembling output shaft and freewheel No. | Designation Special tool | Order number | Explanation Assembly ring 9336 | 000.721.933.60 Dismantling and assembling output shaft and freewheel 38 - 127 Printed in Germany ~ XV, 199238 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembling output shaft and freewheel 0298 38 - 128 Dismantling and assembling output shaft and freewheel Printed in Germany ~ XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls 38 No. | Designation Qty. | Removal Installation 1 | Snap ring 1 | Remove with suitable Install with sultable pliers| pliers and screwdriver (e.g. W 61a) 2 | Disc cartier 1 3 | Freewheel outer ring 1 | Rotate to lift off along with| Rotate clockwise to freewheel cage push onto inner ring along with freewheel cage 4 | Thrust washer 1 5 | Freewheel cage 1 | Mark installation position | Use Special Tool 9336 for reassembly. Press to place into outer ring | carefully out of outer ring | 6 | Thrust washer 1 7 | Snap ring 1 8 | Freewheel inner ring 1 9 | Hollow gear 1 10 | Rectangular ring 1 Replace 11 | Snap ring 1 12 | Output shaft 1] | Dismantling and assembling output shaft and freewheel 38 - 129 Printed in Germany ~ XV, 199238 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembly notes Dismantling 1. Remove snap ring (No. 1) and take off freewheel assembly along with disc carrier and hollow gear. Assembly 1, Place freewheel cage onto outer ring and align. 2. Use Special Tool 9336 to compress freewheel cage and to push it into the outer ring 0698 A- Special Tool 9336 3. Push freewheel outer ring onto inner ring, following a clockwise rotary motion. 4, Determine gap between freewheel inner ring and freewheel outer ring. A minimum gap of 0.1 mm must remain, e098 38-130 Dismantling and assembling output shaft and freewheel Printed in Germany - XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls 38 Dismantling and assembling clutch E No. | Designation |_ Special tool Order number Explanation Assembly tool 9335 000.721.933.50 Dismantling and assembling clutch E Printed in Germany ~ XV, 1992 38-13138 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembling clutch E 38 - 132 Dismantling and assembling clutch E Printed in Germany - XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls 38 Note: No. | Designation Qty. | Removal Installation 1 | Snap ring 1 teeth) disc of brake F 3 | Outer disc 5 Do not confuse with (1.5 mm thick) outer dises of brake F 4 | Inner disc 5 | Retainer ring 1 | Remove with Special Tool | Install with Special Tool 2 | End disc (with internal = | 4 Do not confuse with end | | | | 9335, using a press 9335, using a press 6 | Cup spring Dod Convex side faces re- tainer ring 7 | Thrust cup Place into position with convex side facing 8 | Piston | 1 | To remove, apply com- | Grease round seals down | pressed alr across oll (with Vaseline) and press: feed bore piston carefully in place, | making sure it does not \ bind 9 | Round seal 1 Replace 10 | Round seal 1 Replace 41, | Cylinder 1 Dismantling and assembling clutch E 38 - 133, Printed in Germany ~ XV, 199238 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembly notes Dismantling Assembly 1. Remove retainer ring with Special Tool 1. Fit split retainer ring with Special Tool 9335 9335 and a bar magnet, using a press. and a press, observing the correct position. e708 s7038 A - Special Too! 9335 2. Coat discs with ATF fluid. 8 - Split retainer ring 2. Remove piston by applying compressed air across the oil feed bore. Use a air gun fitted with a sealing sleeve 38 - 134 Dismantling and assembling clutch E Printed in Germany - XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls Measure air gap ‘Standard: 1.16...2.74 mm 1. Use a screwdriver to press snap ring up- wards along its entire circumference and measure air gap with a feeler gauge. If the wear limit has been reached, the entire disc pack must be replaced. 38 Dismantling and assembling clutch E Printed in Germany ~ XV, 1982 38 - 135911 Carrera 2 Automatic Transmission, Gears, Controls 38 Dismantling and assembling brake F No. | Designation ‘| Special tool Order number | Explanation Assembly tool 9335 000.721.933.50 and assembling brake F 38 - 137 Printed in Germany - XV, 199238 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembling brake F 38 - 138 Dismantling and assembling brake F Printed In Germany ~ XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls 38 - Note: No. | Designation Qty. | Removal Installation | | 1) | Snap ring 1 2 | End disc (without internal 1 Do not confuse with end | teeth) disc of clutch E 3. | Inner disc d | 4 | Outer disc 4 Do not confuse with (2.1 mm thick) outer disc of clutch E 5. | Ring (split) 1 | Remove with Special Tool | Install with Special Too! | 9335 and a press 9335 and a press, i observing correct posi- | tion. Stepped side faces | inside. 6 | Cup spring 1 Lugs face inside 7 | Piston 1 | Press out of cylinder from | Grease round seals outside, using a suitable | (with vaseline) and | | tool press carefully into cy- | | linder, making sure the | piston does not bind, 8 | Sealing ring ,o4 Replace } To avoid damage, ex- | pand ring slightly and fit | | | at once | | 9 | Round seal 1 Replace 10 | Rectangular ring } 2] Hooked ends must en- | gage into each other 11. | Cylinder ; 1 Dismantling and assembling brake F 38 - 139 Printed In Germany ~ XV, 199238 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembly notes Dismantling Assembly 1. Remove split ring with Special Tool 9335. 1. Install split ring with Special Tool 9335 and and a bar magnet, using a press. a press. exs30 ease A- Special Too! 9335 B- Split ring 2. Using a suitable tool, press piston out of cylinder from the outside. couse 38 - 140 Dismantling and assembling brake F Printed in Germany ~ XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls 38 Measure gap ‘Standard: 1.45...2.75 mm 1. Use a screwdriver to press snap ring up- wards along its entire circumference and measure air gap with a feeler gauge. If the wear limit has been reached, the complete disc pack must be replaced. 91998 Dismantling and assembling brake F Printed In Germany - XV, 1992 38-141911 Carrera 2 Automatic Transmission, Gears, Controls 38 Dismantling and assembling brake pack CD with spider shaft ase No. | Designation ~ 1 Special too! | Order number __| Explanation Assembly support | 9314 000.721.931.40 Dismantling and assembling brake pack CD with spider shaft 38-143 Printed in Germany ~ Xv, 199238 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembling brake pack CD with spider shaft 38 - 144 Dismantling and assembling brake pack CD with spider shaft Printed In Germany ~ XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls 38 No. | Designation _ Qty. Note: Removal | Installation 1 | Cylinder CD 2 | Support ring 3 | Planetary set 4 | Sun shaft ow | Axial needle roller cage Remove with centering plate and support ring. For dismantling, refer to page 38 - 152 Refer to "Dismantling | and assembling brake D" (refer to page 38 - 152) Hook ends of rectangular rings into each other | 6 | Thrust washer 1 7 | Spider shaft (with hollow 1 | For dismantling, refer to | | gear and intermediate page 38 - 147 | | shatty Note To dismantle, place spider shaft with cylinder CD onto Special Tool 9314. Dismantling and assembling brake pack CD with spider shaft Printed in Germany - XV, 1992 38-145911 Carrera 2 Automatic Transmission, Gears, Controls Dismantling and assembling spider shaft 38 soos No. | Designation 7 | Special too! | Order number __| Explanation Assembly support 9314 000.721.931.40 Dismantling and assembling spider shaft 38-147 Printed In Germany ~ XV, 199238 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembling spider shaft 38-148 Dismantling and assembling spider shaft Printed in Germany ~ XV, 199238 911 Carrera 2 Automatic Transmission, Gears, Controls li eee “PCN sts—<—sCSY No. | Designation Qty. | Removal Installation 1 | Snap ring 1 2. | Front hollow gear 1 3. | Planetary set 1 Do not allow to bind, rotate intermediate shaft to place unit in assembly position 4 | Intermediate shaft 1 Fit rear hollow gear and place both into spider shaft 5 | Thrust washer 1 6 | Axial needle roller cage 1 7 | Thrust washer 1 8 | Snap ring 1 9 | Rear hollow gear 1 410 | Spacer ring 1 11 | Snap ring 1 12 | Spider shaft 1 Note To dismantle and assemble the spider shaft, place it onto Special Tool 9314. Dismantling and assembling spider shaft Printed in Germany ~ XV, 1992 38-149911 Carrera 2 Automatic Transmission, Gears, Controls 38 Dismantling and assembling brake C, C’ and D 0-38 No. | Designation [ se tool Order number | Explanation 1 | Thrust piece 9992 000.721.933.20 2| Assembly sleeve |_ 9383 (000.721.933.90 Dismantling and assembling brake C, C’ and D 38-151 Printed in Germany ~ XV, 199238 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembling brake C, C’ and D 38 - 152 Dismantling and assembling brake C, C’ and D Printed in Germany ~ XV, 199238 911 Carrera 2 Automatic Transmission, Gears, Controls Note: call No. | Designation Qty. | Removal Installation 1 | Centering plate 1 | Observe installation | position 2 | Retainer ring (split) 1 | Remove with Special Too! | Install with Special Tool | 9332 and a bar magnet, | 9332, using a press using a press 3. | Cup spring 1 Center in such a way that it is not squeezed by the retainer ring 4 | Piston C’ | 1 | Toremove, apply com- | Do not confuse with | pressed air across the oil | piston C. Grease seals feed bore with vaseline and push them carefully onto the centering plate, making | sure the piston does not | bind | 5 | Round seal | 1 Replace 6 | Round seal 1 Replace 7 | Outer dise 4 Observe installation (1.8 mm thick) position 8 | Inner disc 2 9 | Outer disc } 4 Observe installation (2.1 mm thick) | position 10 | End disc 1 Observe installation } position 11° | Inner disc | 3 12 | Outer disc | 3 Observe installation | | position 13 | Freewheel (2nd gear) ; 4 Fit into correct position \ Wider section of teeth faces inside 14 | Sun shaft 1 15. | Rectangular ring 2 Ring ends must be hooked into each other 16 | Planetary set 1 17. | Snap ring 1 Dismantling and assembling brake C, C’ and D Printed in Germany ~ XV, 1992 38 - 15338 Automatic Transmission, Gears, Controls 911 Carrera 2 ~ ~ Note: No. | Designation Qty. | Removal Installation 18 | Adjusting outer disc 1 If required, reestablish correct thickness 19 | Inner disc 5 To facilitate assembly, reinstall planetary set first 20 | Outer disc 5 21 | Snap ring 1 | Using Special Tool 9332 | Install with Special Tool | and suitable snap ring 9333, using a press pliers, remove with a press | 22 | Cup spring 1 | 23 | Piston 1 | Toremove, apply com- | Grease seals with | pressed air across the oil | vaseline and press them | feed bore carefully into cylinder, making sure the piston does not bind 24 | Round seal || Replace 25 | Round seal | 1 | Replace | 26 | Retainer ring (split) | 1 | Remove with Special Tool | Install with Special Tool | 9332 and a bar magnet, | 9332, using a press | using a press 27 | Cup spring | 1 | 28 | Piston C | 1 | Toremove, apply com- | Do not confuse with pis- | pressed air across the oil | ton C’. Grease seals with | feed bore vaseline and press care- | fully into cylinder, making | sure the piston does not ; bind. 29 | Round seal 1 Replace | 30. | Round seal 1 Replace | 31 | Woodruff key ; 4 Place exactly into center } of cutout of cylinder CD 32 | Cylinder CD | 38 - 154 Dismantling and assembling brake C, C’ and D Printed in Germany ~ XV, 1992911 Carrera 2 Dismantling and assembly notes Dismantling 1. Remove retainer ring with Special Tool 9332 and a bar magnet, using a press. Automatic Transmission, Gears, Controls 38 3, Remove snap ring with Special Too! 9332 and suitable pliers, using a press. erase ors98 A- Special Too! 9332 A- Special Too! 9332 B - Split retainer ring B - Snap ring 2, Remove pistons C and D by applying 3, Remove retainer ring with Special Tool compressed air across the oil feed bores. 9332 and a bar magnet, using a press. wsa8 orase A. Special Too! 9332 B- Split retainer ring Dismantling and assembling brake C, C’ and D 38 - 155 Printed in Germany ~ XV, 199238 Automatic Transmission, Gears, Controls 911 Carrera 2 4, Remove piston C’ by applying compressed 2. Install retainer ring with Special Too! 9332, air across the poil feed bore. using a press. Assembly 3. Coat discs with ATF fluid. 1. Install snap ring with Special Tool 9333, using a press 4. Place end disc (No. 10) into position so that the center tooth of the three adjacent teeth rests on the three notches (with cast lugs) of cylinder CD A- Special Too! 9333 8 - Snap ring om A- Lugs 38 - 156 Dismantling and assembling brake C, C’ and D. Printed in Germany ~ XV, 1902911 Carrera 2 Automatic Transmission, Gears, Controls 38 5. The outer teeth of the outer discs C’ must ot protrude into the bevelled cutout of the cylinder. 6. Place centering plate in position so that the bevelled cam fits into the corresponding bevelled cutout of cylinder CD. Dismantling and assembling brake C, C’ and D 38 - 157 Printed in Germany ~ XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls 38 Determining air gap of brakes C’, C and D Brakes C’ and C Brake C’ Specification: 0.55...1.97 mm Brake C Specification: 0.63...2.40 mm Determine air gap with a feeler gauge Note To avoid false readings, place centering plate under a suitable load (e.g. Special Tool 9508/1), Brake C’ A.- Special Too! 9508/1 Brake C eae A - Special Tool 9508/1 If the wear limit has been reached, all discs must be replaced Brake D Specification: 1,34...2,39 mm The air gap may be adjusted using the ad- justment outer disc (18) available in a variety of thicknesses. Determine air gap with a feeler gauge. Dismantling and assembling brake C, C’ and D Printed in Germany ~ XV, 1992 38 - 15938 Automatic Transmission, Gears, Controls 911 Carrera 2 Note To avoid false readings, place support ring under a suitable load (e.g. Special Too! 9508/1). A - Special Too! 9508/1 B - Special Tool VW 402 If the wear limit has been reached, all discs must be replaced and the air gap must be re- adjusted with the adjustment outer disc (18). 38 - 160 Dismantling and assembling brake C, C’ and D Printed in Germany - XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls 38 Dismantling and assembling clutch B —=~ soos No. | Designation _ Special tool Order number | Explanation 1] Thrust piece 332 (000.721.933.20 2] Assembly sleeve 9330/1 000.721.933.01 Dismantling and assembling clutch B 38-161 Printed in Germany - XV, 199238 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembling clutch B 38 - 162 Dismantling and assembling clutch B Printed in Germany - XV, 1992Automatic Transmission, Gears, Controls 38 911 Carrera 2 f Note: No. | Designation Qty. | Removal Installation | 1 | Snap ring eo Redetermine thickness if i required 2 | End disc }o4 3 | Inner disc | 4 4 | Outer dise 4 (2.1 mm thick) 5 | Snap ring 1 | Remove with Special Too! | Install with Special Tool 9332 using a press 9330/1 using a press, | checking for correct seating 6 | Tab washer 1 7 | Cup spring 1} Place in correct position 8 | Piston 1 | To loosen, apply com- Grease round seals | pressed air across the (use vaseline) and press | oil feed bore and take carefully into cylinder F, out by knocking lightly making sure the piston on a wooden support does not bind 9 | Round seal 1 Replace 10 | Round seal 1 Replace 11 | Rectangular ring 1 Hook ends into each other 12 | Cylinder 4 Dismantling and assembling clutch B Printed in Germany - XV, 1992 38 - 16338 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembly notes Dismantling 1. Remove snap ring with Special Too! 9332 using a press. 6028 A = Snap ring 2. To loosen, apply compressed air across the oil feed bore and take out by knocking lightly on a wooden support. @ Assembly 41. Fit snap ring, placing internal section of Special Tool 9330/1 into position and pushing snap ring up to the taper. Then use outer section of Special Tool 9330/1 and a press to push the snap ring into the groove. A = Special Tool 9330/1 B = Snap ring 2. Coat discs with ATF fluid. 38 - 164 Dismantling and assembling clutch B Printed in Germany ~ XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls 38 Measuring the air gap Standard: 1.23...1.57 mm Note The air gap can be adjusted with the snap ring (No. 1) that is available in three thick- nesses (1.5 - 2.0 - 2.5 mm). 1. Use a screwdriver to press snap ring up- wards along its entire circumference and measure air gap with a feeler gauge. If the wear limit has been resached, the entire disc pack must be replaced and the thick- ness of the snap ring must be redetermined. ovr98 Dismantling and assembling clutch B Printed in Germany - XV, 1992 38 - 165911 Carrera 2 Automatic Transmission, Gears, Controls 38 Dismantling and assembling clutch A Dismantling and assembling clutch A Printed in Germany - XV, 199238 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembling clutch A 38 - 168 Dismantling and assembling clutch A Printed in Germany ~ XV, 1992911 Carrera 2 Automatic Transmission, Gears, Controls 38 Note: No. | Designation Qty. | Removal Installation 1 | Drive shaft 1 | Separate from cylinder by tapping lightly on a wooden support 2 | Rectangular ring 2 3 | Round seal 1 Replace, coat with vaseline | 4 | Snap ring 1 | Remove with a suitable Install with a suitable thrust piece (e.g. plate of | thrust piece (e.g. plate 9329), using a press of 9329), using a press 5 | Disc pack AB 1 6 | Spring disc 2 7 | Adjustment outer disc 1 | Record thickness for Refit old discs or use reassembly new disc of the same thickness | 8 | Inner dise 5 Wear limit: Thickness | below 1.5 mm 9 | Outer disc 5 | 10 | Cup spring 1| Install in correct position 11. | Piston 1 | Toremove, applycom- | Grease sealing rings pressed air across oil (use vaseline) and press feed bore carefully into cylinder, | making sure the piston does not bind 12 | Round seal 1 Replace | 13. | Round seal 1 Replace | 14 | Cylinder 1 Dismantling and assembling clutch A Printed in Germany ~ XV, 1992 38 - 16938 Automatic Transmission, Gears, Controls 911 Carrera 2 Dismantling and assembly notes Dismantling 1. Press down disc carrier with a suitable thrust piece (e.g. plate of 9329) using a press, and take out snap ring. A- Snap ring B - Plate of Special Too! 9323 2. To remove piston, apply compressed air across the oil feed bore. Assembly 1. If the wear limit of the inner discs has been reached, the entire disc pack must be re- placed along with the old adjustment outer disc. 2. Coat dises with ATF fluid. 38 - 170 Dismantling and assembling clutch A Printed in Germany ~ XV, 1992911 Carrera 2 Automatic transmission, gears, shafts 38 Determining the end clearance Specification: 0.2...0.4 mm 3. Using some grease (use vaseline), stick the removed adjusting washer to the rear trans- Note mission case and put housing carefully into Check the end clearance whenever the trans- position. mission has been reassembled and readjust if required, using adjusting washer No. 12 (refer to page 37 - 105). 1, Assembly transmission (complete with spur gear drive and front transmission cover). ‘ 2. Screw centering pins 9321 into transmission oN | case and apply some grease (vaseline) to ey TH stick paper gasket to sealing surface. i A | A : ad oe A-- Centering pins 9321 4. Tighten all mounting screws to 46 Nm (34 ftlb). 5. Mount measuring sleeve of Special Too! 9838 with three mounting screws on the stator shaft in such a manner that no play cetae remains. A- Centering pins 9321 B - Gasket 28 Determining the end clearance 38-171 Printed in Germany — XX, 199438 Automatic transmission, gears, shafts 6. Slide measuring device of Special Tool 9338 over drive shaft teeth and tighten with clamping screw so that it cannot be titted. 7. Set measuring sleeve to zero with a certain preload. 8. Determine end clearance by pulling the handle. Repeat measurement several times. Note It a deviation is detected, remove rear trans- mission housing again and fit a thinner or thicker adjusting washer as required. Recheck end clearance afterwards. 911 Carrera 2 38-172 Determining the end clearance Printed in Germany — XXI, 199439 Final drive, differential 911 Carrera 2 Disassembling and assembling the long joint flange 39 - 102 Disassembling and assembling the long joint flange Printed in Germany - VI, 1990911 Carrera 2 Final drive, differential 39 Note: No. | Designation Qty. | Removat Installation 1 | Circtip 1 2 | O-ting 1 Replace 3. | Bearing cap 1 4. | Rotary shaft seal 1 Pack space between dust lip and sealing lip with grease (e.g. Shell 8420) and press in flush with sui table thrust piece 5. | Ball bearing 1. | Press off jointly with bear- | Press in until it bottoms ing cap with a suitable pressure piece 6 | Protective ring 1 7 | Joint flange 1 Disassembling and assembling the long joint flange Printad in Germany — XV, 1992 39 - 103911 Carrera 2 Final drive, differential 39 Removing and installing the rotary shaft seal for the short joint flange Removing Note The rotary shaft seal can also be replaced with the transmission in built-in condition. 1. Unscrew the hexagon screw for the joint flange and remove flange. 40830 2. Lever out rotary shaft seal with VW 681. Installing 1. Press in rotary shaft seal flush with suitable pressure piece. 2. Tighten hexagon screw for joint flange with 46 Nm (34 ftlb) Removing and installing the rotary shaft seal for the short joint flange 39 - 105 Printed in Germany ~ Vi, 1990911 Carrera 2 Final drive, differential 39 Sealing off the driving shaft 1. Drain ATF 2. Remove engine with gearbox (do not unbolt engine from gearbox. 3. Remove intermediate plate (see page 37 - 107). 4. Remove bearing cap with Torx insert T 27 and replace rotary shaft seal. Pack space be- tween dust lip and sealing lip with grease (e.g. Shell 8420) Press-in depth 2.0+ 0.5 mm. A = Rotary shaft seal an 5. Fit bearing cap with new O-ring and tighten fixing screws with 10 Nm 6. Remove snap ring for bearing cap at inter- mediate plate and pull out cap. we A = Snap ring B = Rotary shaft seal 7. Replace rotary shatt seal. Pack space between dust lip and sealing lip with grease (e.g. Shell 8420). Press-in depth 2.0+ 0.5 mm 8. Fit new O-ring and wet with ATF. 9. Insert bearing cap and fit snap ring. 10. Fill with ATF. Sealing off the driving shaft Printed in Germany ~ XV, 1992 39 - 107911 Carrera 2 Differential, Transaxle System 39 Adjusting the preload of the spur gear taper roller bearings Adjusting spur gear II (intermediate gear) 1. Determine and record dimension ‘a’ (e.g. 45.90 mm). 1000-99 2. Fit complete spur gear Il and determine dimension "b" (e.g. 44.65 mm). Record measured value. 3. Determine shim thickness by deducting dimension "b* from dimension “a and adding a constant value of 0.22 mm (pre- load and thickness of compressed gasket), Note The constant value is 0.22 mm for all trans- missions. Example Dimension "a"e.g. 45.90 mm Dimension "b' e.g. - 44.65 Constant Shim thickness Note Always round shim thickness up or down to the nearest 0.05 mm figure. Adjusting the preload of the spur gear taper roller bearings Printed in Germany - XV, 1992 39 - 108a39 Differential, Transaxle System 911 Carrera 2 Adjusting spur gear | (drive gear) 1. Remove intermediate plate. 2. Remove adjusting shim (refer to page 37 - 108, No. 16). 3. Remove spur gear II (intermediate gear) for measurement. 4, Bolt up cover with intermediate plate (but without gasket). Tighten all screws and bolts to 23 Nm (17 fib). 5. Internal puller (e.g. Schrem 20 - 30) into spur gear teeth. 6. Fit dial gauge holder VW 387 with dial gauge and zero out dial gauge with a preload of 2mm. 7. Move spur gear | up and down on internal puller and read off play on dial gauge (e.g. 1.18 mm). 1029 39 A = Dial gauge extension Internal puller Note Do no turn or tilt the spur gear when measur- ing the clearance. Repeat measuring process several times. 8. Determine shim thickness. Measured value plus 0.20 mm (preload and thickness of compressed gasket) equals shim thickness Note The constant value is 0.20 mm for all trans- missions. Example Measured value 1.18 mm Constant value + 0.20 mm Shim thickness 1.38 mm 9. Fit a shim of the determined thickness (1.38 mm in our example). Note Always round shim thickness up or down to the nearest 0.05 mm figure. 39- 108b Adjusting the preload of the spur gear taper roller bearings Printed in Germany - XV, 1992911 Carrera 2 Differential, Transaxle System Removing and installing differential and drive pinion 39 eo. No. | Designation |” Special too! Order number | Explanation Socket 9330 000.721.933.00 | Removing and installing differential and drive pinion 39- 109 Printed in Germany ~ XV, 199239 Differential, Transaxle System 911 Carrera 2 Removing and installing differential and drive pinion 39-110 Removing and installing differential and drive pinion Printed in Germany ~ XV, 1992911 Carrera 2 Differential, Transaxle System 39 ~ Note: ~ No. | Designation Qty. | Removal | Installation 1 | Plug 1 Tighten to 50 Nm | (37 ftlb) 2 | Seal \o4 Replace 3 | Plug with solenoid }o4 Tighten to 50 Nm | (37 ftlb) 4 | Seal 1 Replace 5 | Pan head screw 4 | Remove with Special Tool | Tighten to 23 Nm 9330 (17 ftlb) 6 | Halfshaft flange 1 For dismantling, refer to | page 39 - 102 7 | Hexagon head bolt 1 | Tighten to 46 Nm | | | G4 ftib) | 8 | Halfshaft flange lacs | | 9 | Hexagon head bolt | Tighten to 23 Nm | | (17 ftlb) | 10 | Spring washer Wy | 41 | Bracket 1| 12 | Transmission side cover 1} | 13 | Round seal 1 Replace, oil lightly 14. | Shaft seal 1 | Replace Pack space between | | dust lip and sealing lip with grease (e.g. Shell 8420) and press in flush 15. | Differential 1 16 | Taper roller bearing outer 1 | race 117. | Adjusting shim “S1" X | Record thickness for Redetermine thickness | | refitting if required | 18 | Taper roller bearing outer d | race | | 19. | Adjusting shim “S2" X | Record thickness for Redetermine thickness | refitting if required 20 | Pan head screw 3 Tighten to 10 Nm (7 ttlby Removing and installing differential and drive pinion Printed in Germany - XV, 1992 39-11139 Differential, Transaxle System 911 Carrera 2 Note: —_ No. | Designation Qty. | Removal | Installation 21 | Bracket 1 22 | Bearing cover 1 23 | Round seal 1 Replace 24 | Shaft seal 1 Replace. Pack space between dust lip and sealing lip with grease | (e.g. Shell 8420). | Press in to depth of 20+ 05mm 25 | Pan head screw 6 Tighten to 50 Nm (37 ftlb) 26 | Drive pinionm with bear- 1 | To drive out, use a plastic | Observe matching | ing assembly | | hammer to apply light number, readjust it | | blows on the drive pinion required | | head 27 | Adjusting shim “S3" X | Record thickness for Redetermine thickness | reassembly | if required 28 | Round seal 1 Replace, oil lightly 29 | Breather 1 30 | Screw-in flange 2 Tighten to 35 Nm (26 fb) 31 | Seal 2 Replace 32 | Plug eee Tighten to 25 Nm | (18 ftlb) 33 | Seal 2 Replace 34 | Rear transmission 1 housing 39-112 Removing and installing differential and drive pinion Printed in Germany ~ XV, 1992911 Carrera 2 Differential, Transaxle System 39 Removal note Mount rear transmission case with converter housing on assembly support. 90500 A - Converter housing (spare part) Removing and installing differential and drive pinion 39-113 Printed in Germany ~ XV, 1992911 Carrera 2 Differential, Transaxle System 39 Dismantling and assembling differential Dismantling and assembling differential 39-115 Printed in Germany - XV, 1992911 Carrera 2 Differential, Transaxle System 39 Dismantling and assembling differential i Or P 4 £

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