Assembling Shafts - Porsche 996 TT Repair Manual

Assembling shafts

Note
• The overview diagram of the input shaft is provided in the chapter disassembling transmission under
Disassembling input shaft .
1. Clamp shaft with special tool socket wrench insert 9282 in the vice.
2. Assemble synchronization if necessary. The synchronization consists of parts 19 to 14 and 11 in the
overview. Pay attention to correct seating of the steel synchronising rings −A− and the driver dogs −B− .
The driver dogs with spring and ball must align with the dotting marks on the shift collar. Make sure
furthermore that the rectangular indentations of the synchronising rings are positioned above the driver
dogs.
3. Check the synchronising rings for wear. check synchronising rings by pushin them onto the gear wheels
and measuring the gap −A− with a feeler gauge.
Installation dimension (new):
Wear dimension:
4. Push needle−roller bearing (no. 21 in overview), 3rd gear loose gearwheel (no. 20 in overview)
and synchronisation onto input shaft.
5. Heat bearing inner race (no. 13 in overview) to 120°C and push onto input shaft.
6. Push 4th gear loose gearwheel (no. 12 and 10 in overview) and thrust plate (no. 9 in overview) onto input
shaft.
7. Heat bearing inner race (no. 6 in overview) to 120°C and push onto input shaft.
8. Fit clamping plate with short lock (no. 5 and 8 in overview), four−point bearing (no. 4 in overview)
and shift fork (no. 7 in overview) onto input shaft.
9. Heat bearing inner race (no. 3 in overview) to 120°C and push onto input shaft.
10. Heat cylindrical−roller bearing (no. 2 in overview) to 120°C and push onto input shaft.
11. Screw new hexagon nut onto input shaft.
Tightening torque: 250 Nm (185 ftlb.)
Assembling shafts
einordnung
min. 0.9 mm
0.6.....0.7 mm
1943