Page 1 Workshop Manual DR. ING. h. c. F. PORSCHE Aktiengesellschaft...
Page 2 The Workshop Manual is only for the internal use of the Porsche Dealer Organization. @ 1977 Dr. Ing. h.c. F. Porsche Aktiengesellschaft Sales, D-7140 Ludwigsburg All rights resewed - Printed in Germany XX, 1986 WKD 481 621 Print No. W 42-608-126-l...
Page 3: List Of Repair Groups
List of Repair Groups General Technical Data Paae 0.1 Repair Groups Group Maintenance, Self-diagnosis Engine Engine, Crankcase Engine, Crankshaft, Pistons Engine, Cylinder Head and Valve Drive Engine, Lubrication Engine, Cooling Fuel Supply Air Flow Controlled Fuel injection Exhaust System/Emission Contrds Starter, Power Supply, Cruise Control Ignition System Transmission...
Page 4: Table Of Contents
Table of contents Volume III Page General Data data 30-0101 Technical 30-0105 Tightening torques Torque Converter 32-101 Removing and installing torque convener Removing and installing selector lever cover frame 37-101 Removing and installing selector lever cable 37-103 37-105 Adjusting selector lever cable Removing and installing starter locking and backup light switch 37-107 37-109...
Page 5: Table Of Contents
Volume III Table of contents Disassembling and assembling secondaty pump ....38-l 55 ....Disassembling and assembling gear assembly 38-l 57 Disassembling and assembling one-way clutch ....38-163 and assembling clutch K 1 ....Disassembling 36-l 69 Disassembling and assembling clutch K 2 ....38-177 Differential I Transaxle system Removing and installing final drive...
Page 6 General Data 4 - SPEED AUTOMATIC TRANSMISSION (UP TO '86 MODELS) 1 - Front converter casing 2 - Automatic transmission 3 - Final drive Transmission Type installed A 28.01 928 S, USA series '84 models Japan A 28.02 928 S, Special option Europe / rest...
Page 7: Technical Data
General Data Technical Data 4-speed automatic transmlsslon (‘87 models onward) 1 - Front converter casing 2 - Automatic transmission 3 - Final drive Key-number Equipment Installed In model Type A28.12 928 S 4 USNJap. 87188 A28.14 928 S 4 R.d.W. 87188 A28.16 928 S 4 worldwide...
Page 8 General Data Technical Data Tmsmlsslon DeslgnatTon A 28 05065 @zFc,985 1 = 5 - speed transmission 6 = Automatic Transmission for 8 cylinder vehicles Limited-slip differential 40 % Country code Transmission type A 28 = four speed automatic A 22 = three-speed automatic G 28 = five-speed manual transmission...
Page 9 General Data Technical Data numbers Transmlssion (12 dlglts) A2814 Serlal Index for varlants Model year number wlthln the assembly number e.g. 00903 J = 1988 0 = no differential K = 1989 L = 1990 1 = normal differential 2 = ZF limited slip differential M = 1991 3 = proportional slip differential Note:...
Page 10 General data A28.0 1/04/07/l 2 R8.02/03/05/06/08/09/11/14/16/18 Fully automatic 4-speed sun-an&planet transmis A 28/t 6 Ratios 3,87 1st gear 2941 2,25 2nd gear 3rd gear I,44 1 ,oo 1 ,oo 4th gear 5,59 RDckw&tsgang 5,14 Final drive Drive pinion without hypoid displacement Final drive ratio 15 : 33 i = 2,200 14 : 33 i = 2,357 (A 28.02/05/08)
Page 11: Tightening Torques
General TIGHTENING TORQUE FOR AUTOMATIC TRANSMISSION Location Description Threads Material Torque Nm (ftlb) Primary pump Bolt 20 (14) to front cover Plug Bolt MlOxl 10.9 14 (10) (converter) Front cover Bolt 13 19) to transmission case Support flange Bolt 10.9 11 (8) to transmission case...
Page 12 General TIGHTENING TORQUE FOR AUTOMATIC TRANSMISSION Location Description Material Torque Threads Nm (ftlt Lower cover Bolt 4 (3) with reinforcement plate Lower cover assy. Bolt 8 (6) to transmission case Plug (test connection Plug M8xl 13 (9) for modulating, governor and operating pressure) Vacuum unit bracket...
Page 13 General Data Tightening torques (automatic transmission) Location Tightening Torque Nm (ftlb) Thread Threaded plug (ATF pan) MlOxl 22 (12) ATF pan to transmission case 8 (5.9) Front converter casing to transmission case 23 (17) Carrier plate to converter 46 (34) Rear transmission cas to transmission...
Page 14 Torque Converter TOOLS Remarks Special Tool Description 9216 holder Transmission 9301 Grip plate 9310 Mandrel Standard tool Depth gauge Removing and Installing Torque Converter VIII, 1984 Printed in Germany...
Page 15 Torque Converter REMOVING AND INSTALLING TORQUE CONVERTER i .-.-. -.-.-.- .-.-.-. -‘-‘-‘-‘-‘- /I-. y.<- ’ i .c’ 0-I @ -9 4123 32-102 Removing and Installing Torque Converter Printed in Germany...
Page 16 Clutch, Automatic Torque Converter Note When: Description Removing Installing !tY. Mounting bolt Tightening torque: 46 Nm (34 ftlb) Panhead bolt Tightening torque: 23 Nm (17 ftlb) Washer Front converter casing Torque Lift carefully Renew if badly worn converter with Special Tool particles 9301...
Page 17 Clutch, Automatic Torque Converter NOTES ON REMOVING AND INSTALLING -yp? pf./ Removinq ,. , J ,/ ‘” / ;gzp,$ : l.Remove transmission. 2.Using Special Tool 9216, attach transmission assembly support. 6.Attach Soecial Tool 9301 torque converter and carefully lift converter. 3.Place transmission upright...
Page 18 Clutch, Automatic Torque Converter l.Rinse torque converter with Special Tool 9310. To rinse, fill converter with approx. 11 of kerosine, insert rinsing and use a hand drill turn speed. Then drain kerosine through drain plug. Repeat rinsing 2 - 4 times until kerosine drained...
Page 19 Automatic Transmission/Controls, Case REMOVING AND INSTALLING SELECTOR LEVER COVER FRAME Removing 1. Remove selector lever grip and take off rubber boot. 2. Move selector lever to position “2” and push rear locking bar forward against stop with a suitable tool (e. g. scribe). 6.
Page 20 Automatic Transmission/Controls, Case 6. Position selector lever between “R” 9. Attach gate in selector lever, install “P”, disconnect gate on selector lever and rubber boot in correct position push forward. install selector lever grip. 7. Push front locking bar toward rear until it IO.
Page 21 Automatic Transmission/Controls, Case REMOVING AND INSTALLING SELECTOR LEVER CABLE Removing 7. Disconnect selector lever cable on trans. mission lever and detach cable sleeve on brackets. 1. Unscrew ground strap of battery on body. -:+@*> : ---, i F ,/’ 2. Remove selector lever grip and take off rubber boot.
Page 22 Automatic Transmission/Controls, Case Note: If light opening of gate and letter “N” not exactly opposite each other in cover frame, remove cover frame again and reposi- tion selector lever base in slots. 6. Mount selector lever cable on transmission as specified. Installing 7.
Page 23 Automatic Transmission/Controls, Case ADJUSTING SELECTOR LEVER CABLE 1. Move selector lever to position “N”. Note: Bolt for range selector lever must be tightened for adjustments. 2. Place range selector lever on transmission in “N”. 3. Adjust ball end on cable that attachment possible without tension.
Page 24 Automatic Transmission/Controls, Case REMOVING AND INSTALLING STARTER LOCKING AND BACKUP LIGHT SWITCH Removing 4. Pry off plug carefully with two screw 1. Disconnect selector lever cable. drivers applied on cable outlet and bar. ‘/ -,fy!y;@-@+-q i3 ? .-” .-w-y _.. YQ;)(: .. 2 -‘,&...
Page 25 Automatic Transmission/Controls, Case 2. Install range selector lever that lug on switch engages. Move range selector lever to position “N”. 3. Install and tighten range selector lever screw with 10 Nm (7 ftlb). 4. Adjust switch and connect plug (see page 37 - 109).
Page 26 Automatic Transmission/Controls, Case ADJUSTING STARTER LOCKING AND BACKUP LIGHT SWITCH I. Insert locating pin made of 4 mm dia. welding wire for 4 mm dia. drill) through lug into locating bore in switch housing. 2. Tighten switch mounting screws with 10 Nm (7 ftlb) and pull out locating pin.
Page 27 Automatic Transmission/Controls, Case CHECKING ADJUSTMENT OF SELECTOR LEVER CABLE STARTER LOCKING/BACKUP LIGHTSWITCH Move selector lever to position “N”. 6. Starting engine should only be possible in “p” or ,TN”, engine at fast idle speed. Pull up parking brake lever and press down on brake pedal for following tests.
Page 28 Automatic Transmission/Controls, Case NOTES ON REMOVING AND INSTALLING Removing l.Remove and bottom halves filter(l6-valve engines only) 2.Disconnect control cable engine..A,. /#-., CA” 32-valve engines ('87 models onward) 3.Sever bowden cable behind threaded connector. 16-valve engines 4.Disengage control cable from...
Page 29 Automatic Transmission/Controls, Case 5.Carefully lift guide. 2.Install clamp correctly attach spherical head with nut. A = Clamp 6.Detach control cable from actuat- and pull toward rear. 3.Attach Bowden cable transmission 4.Adjust cable control pressure (see page 37 - 115). Installing: l.Carefully feed control...
Page 30 Automatic Transmission/Controls, Case CONTROL PRESSURE CABLE, ADJUSTING Note: Correct adjustment Bowden cable control pressure vitally important faultless operation transmission. l.Set idle speed. 2.Take up play throttle cable. 3.Adjust spherical head control cable until cable be installed without strain. 32-valve engines models) m ’...
Page 31 Automatic Transmission/Controls, Case TOOLS Description Special Tool Remarks Universal transmission jack Standard, e. g. from Hahn, Metallbau GmbH 7012 Fellbach Holding chain 9164 Removing and Installing Transmission Printed in Germany VIII, 1984 37.117...
Page 32 Automatic Transmission/Controls, Case REMOVING AND INSTALLING TRANSMISSION Removing 5. Disconnect control cable on throttle housing. 1. Unscrew battery ground strap on body. 2. Disconnect multiple pin plugs in spare wheel well and pull out wires from below. 6. Disconnect oxygen sensor wire on central fuse/relay panel and pull out from below (USA cars).
Page 33 Automatic Transmission/Controls, Case 12. Remove rear axle cross member/trans 16. Disconnect selector lever cable on trans- mission suspension mounting bolts. mission lever and unscrew cable sleeve on holder and case. 13. Support transmission on stabilizer with Special Tool 9164 (if necessary, lift trans- mission on transmission support slightly).
Page 34 Automatic Transmission/Controls, Case 18. Pull off vacuum hose on modulating Disconnect control cable on operating pressure box. rod. 19. Disconnect control pressure cable on transmission. This is done by pushing locking bar of guide in direction of arrow (arrow A) and turning guide counter- clockwise (arrow 6).
Page 35 Automatic Transmission/Controls, Case 22. Lift transmission slightly and disconnect I. Place central tube in installed position holding chain. with a suitably thick block of wood and coat splines on central shaft with Optimoly 23. Lower transmission only far enough that central tube/transmission mounting bolts...
Page 36 Automatic Transmission/Controls, Case 3. Install and slightly tighten accessible bolts 9. Lower universal transmission jack. on central tube flange. 10. Install rear axle and tighten all bolts 4. Lift transmission, remove block of wood and except for two transmission mount take out brace again.
Page 37 Automatic Transmission/Controls, Case ADJUSTING TRANSMISSION SUSPENSION The transmission mounts have to be adjusted Note: to avoid tension in the transmission suspension and to also guarantee good After tightening the mounting bolts there insulation. must be at least 1 mm clearance between the transmission case and stop on side of transmission...
Page 38 Automatic Transmission/Controls, Case TOOLS Lq-- ..~. ,‘\ -. 4 -‘* n, ,a’. Description Special Tool Remarks Support rail Standard (e. g. Kukko, Size 1) Disassembling and Assembling Front Printed inGermany - VIII, 1984 37-125 Converter Housing...
Page 39 Automatic Transmission/Controls, Case DISASSEMBLING AND ASSEMBLING FRONT CONVERTER HOUSING ‘i ’ \,? i/ 4’ 3 “, Printed in Germany Disassembling and Assembling Front Converter Housing 37-126...
Page 40 Automatic Transmission/Controls, Case Description Note When: Special Removing Installing Instructions Circlip Drive flange Press out Press into case with grooved ball bearing (no. 4) Spacer Grooved ball Press off with Heat to approx. bearing support rail, 120 “C/250 “F e. g. Kukko. and push on to size 1 drive flange...
Page 41 Automatic Transmission/Controls, Case DISASSEMBLING ~ANDASSEMBLlNG FRONT CXJfWEf?TEWfGUSING Disassembling Assembling 1. Remove circlip and press out drive flange. 1. Install both circlips in converter housing. ~~~- 2. Heat grooved ball bearing to about ‘1 120 “C/250 “F and press bearing on drive flange against shoulder with a suitable piece of pipe applied on bearing inner...
Page 42 Automatic Transmission/Controls, Case 4.Insert spacer sleeve and using suitable piece pipe, press front deep-groove ball bearing over inner race until bearing contacts circlip. c- ‘r-“T -_ -’ -71 _~ 1% ~~ p-7 ,.- .--- -- i.. - ,:.; ,I--?! Note: Place a suitable pressure...
Page 43 Automatic Transmission/Controls, Case DISASSEMBLING AND ASSEMBLING FRONT CONVERTER CASING ('87 MODELS ONWARD) XVI,1987 37 - 130 Disassembling and Assembling - Printed Germany Front Converter Casing ('87 Models Onward)
Page 44 Automatic Transmission/Controls, Case Note when: Removing Designation Installing Circlip Press Drive flange Press after insert- deep-groove ball bearing (No. Deep-groove Pull with puller Heat casing approx. ball bearing (e.g. Kukko, size 120°C and press as possible with a suitable piece pipe.
Page 45 Automatic Transmission/Controls, Case NOTES FOR ASSEMBLY AND DISASSEMBLY Disassembling 1. Remove circlip and press 2.Using puller (e.g. Kukko, size drive flange. pull deep-groove ball bearing drive flange. r’ll 11 ‘1 i &., rz-i r -~ 2;‘ ..&f&‘- &...
Page 46 Automatic Transmission/Controls, Case 2.Press drive flange as far as it will Note: To prevent deep-groove ball bearing (No.51 movino as the flange pressed, position suitable piece pipe against bearing outer race as a support. 37 - 130 c - XVI,1987 Printed Germany Disassembling...
Page 47 Automatic Transmission/Controls, Case TOOLS Description Special Tool Remarks Pressure pad 9180/l P 254 Mandrel I I, 1984 Removing and Installing Rear Printed in Germany - VI Transmission Case...
Page 48 Automatic Transmission/ContruIs, Case REMOVING AND INSTALLING REAR TRANSMISSION CASE I- ., ;‘, 9 I(('i _ 1’ ‘{j 5 ,- , ~_ , I& ,,;- ;p. ji ~1, /- - i i' 1 ii..k . ,r I.\ / iJ Ii' 37-132 Removing and Installing Rear Transmission Case...
Page 49 Automatic Transmission/Controls. Case Qty. Note When: Special Removing Installing Instructions Bolt Torque: M 10x55 42 Nm/30 ftlb Bolt Torque: M 10x40 42 Nm/30 ftlb Washer Rear transmission case Race Insert after installing case Gasket Replace Seal Drive out with Replace, drive suitable screw- in to correct driver...
Page 50 Automatic Transmission/Controls, Case REMOVING AND INSTALLING REAR TRANSMISSION CASE Removing ---..-+;;R fimkkive-si=&+e (see page 39 101). 2. Remove case mounting bolts. Note: Hold seal on special tool with a small amount of grease and drive in seal that sealing lip faces automatic transmission.
Page 51: Removing And Installing Rear Transmission Case
Automatic Transmission/Controls, Case TOOLS Description Remarks Special Tool 9216 Holder 9301 Grip Mandrel 9310 Depth gauge Standard tool 9321 Centering pins Standard tool Puller Made locally Pressing in tool (steel pipe 45 x 5 x 40 mm with welded cover and 11 mm dia.
Page 52 Automatic Transmission/Controls, Case REMOVING AND INSTALLING REAR TRANSMISSION !---T A J: 1 r;y22 ,-.-. i .-._.- ‘.“ir, -.-.-. z.;.-.-.-. 11 12 13 14 37-136 Removing and installing Rear Transmission Printed in Germany...
Page 53 Automatic TransmisslonlControls, Case Note: Qty. Installation Des&nation Torque: Bolt 46 Nm I33 ftlb Washer Holder Torque: Collar nut 46 Nm / 33 ftlb Torque: 46 Nm / 33 ftlb Washer Torque: Bolt 46 Nm / 33 ftlb Washer Final drive O-ring Replace, coat with ATF Shim “S3”...
Page 54 Automatic Transmission/Controls, Case Note When: Description Removing Installing Shim Note number and Recalculate, thickness necessary reinstallation O-ring Replace, coat with O-ring Replace, coat with Panhead bolt Tightening torque: 6 Nm (4.4 ftlb) Washer ATF reservoir Mounting bolt Tightening torque: 46 Nm (34 ftlb) Panhead bolt Tightening torque:...
Page 55: Removing And Installing Rear Transmission
Automatic Transmission/Controls, Case REMOVING AND INSTALLING REAR TRANSMISSION Removing 5. Position transmission upright and remove converter mounting bolts through openings in housing. 1. Remove transmission. 6. Remove converter housing mounting bolts 2. Mount transmission in assembly stand with and take off housing. Special Tool 9216 and drain final drive oil.
Page 56 Automatic Transmission/Controls, Case Installing 2. Mount Special Tool 9301 on torque converter. Note: The outer seal on the rear transmission 3. Coat drive flange and bearing journal of between the transmission case and final converter with a multi-purpose grease drive could be missing due to manufacturing containing MoS, additives.
Page 57: Shims For Bearing Assembly
Automatic Transmission/Controls, Case Note: 7. Install shims of determined thickness and bearing assembly on output shaft. If ATF smells burnt or contains metal particles, torque converter and ATF cooler ’ must be flushed. /q?+- ‘I If ATF sump contains metal particles, torque converter has to be replaced.
Page 58 AutomatlcTransmlssion/Controls, Case 8. Tighten flange nut for drive pinion to speci- fied torque and lock by upsetting the flange 9. Adjust drive pinion and ring gear (see page 39 - 125). 10. Install transmission and check adjustment of selector lever and control pressure ca- bles.
Page 59 Automatic Transmission/Controls, Case TOOLS P-l@@\ 8 -1. f$-- ” ( 3~) YI^. ---+--P Designation Special Tool Remarks Holder 9216 Assembly support 9316 Mandrel 9119 Measuring bridge 9313 Depth gage Commercia available Circlip pliers Commercia available (e.g. Hazet"1847 - 2) Spacer sleeve 9312 Measuring...
Page 60 Automatic Transmission/Controls, Case DISASSEMBLING AND ASSEMBLING TRANSMISSION Disassembling 5.Unscrew combination bolts l.Attach transmission to assembly remove ATF pan with ATF reservoir. support with Special Tool 9216. Z.Remove final drive with bearing 101). assembly (see page 39 - 3.Remove rear transmission case (see page 37 - 131).
Page 61 Automatic Transmission/Controls, Case 19.Unscrew hex bolt and remove Zl.Remove vacuum-control unit after drive-range selector lever. unscrewing socket-head bolts. ZO.Remove starter-interlock switch 22.Remove pressure unit B 1 and after unscrewing mounting bolts. modulating pressure control valve. ----;-.. “’ r’ 6”--; ,,.\- \>...
Page 62 Automatic Transmission/Controls, Case 23.Remove kickdown solenoid 25.Remove plastic guide and roller. valve and injector tube. pLypc%z-< 1-4, ’ ‘,I ,?‘c.$ ’ f , “g n *..K ._ q” --’ ,c” - r-7 24.Remove parking lock with paw1 and expander spring. 26.Remove secondary pump by...
Page 63: Disassembling And Assembling Transmission
Automatic Transmission/Controls, Case 27.Remove O-ring and backer. 29.Unscrew socket-head bolt remove with tube. The oil tube has been discontinued as of model year ‘87. d.,$ ,’ .‘,i 28.Remove circlip and sprung linkage. The circlip has been discontinued as of model year '87.
Page 64 Automatic Transmission/Controls, Case 35.A modified controller drive gear 31.Withdraw cover. was fitted as of approx. December 1986. With this design, 32.Withdraw centrifugal-force remove spacer. controller after swinging back axial holder. A = Spacer 8 = Circlip 33.Remove axial holder. 36.With a suitable pair of pliers...
Page 65 Automatic Transmission/Controls, Case 37.Remove front cover by unscrewing 39.Pull clutch K 1 with brake band combination bolts, screwing B 1 from gearset. bolts into the threaded holes and using these to pull cover. 40.Remove plates B 3. 41.As of transmission No.
Page 66 Automatic Transmission/Controls, Case 47.Withdraw pressure unit B 2. 44.Tilt brake band B 2 and remove. 45.Unscrew socket-head bolt, withdraw shaft and remove detente plate. -y”’ ,. / /’ I Screw two 48.Unscrew hex bolts. bolts into approx. 80 mm long and release two opposite holes...
Page 67 Automatic Transmission/Controls, Case Assembling Note: When assembling, coat bearings Z.Insert O-ring and sealing ring. and friction surfaces with ATF. Screw in threaded plug with Soak new brake bands and coated sealing ring and tighten. plates in ATF for approx. 1 hour Tightening torque 10 Nm (7 ftlb).
Page 68 Automatic Transmission/Controls, Case 4.Grease grooves in support flange G.Position thrust washer right round (positioning lug engages K 2. Insert teflon rings press into grooves until joints support flange). (arrowed) are closed. ~-y.q,\ -“,p” ‘\ ._ F e :2%- -.i z “‘p a\ ..A\‘.
Page 69 Automatic Transmission/Controls, Case ll.Push clutch K 2 onto gearset. 8.Recheck to ensure that teflon rings are correctly seated support flange. 9.Press brake band B 2 as close together as possible at the support lugs and insert right round in case. lO.Place greased split...
Page 70 Automatic Transmission/Controls, Case 14.Check installation position 16.Insert plates plate brake gearset. The gearset position 8 3 right way round. correct when the upper edge of the connector element (arrowed) is lower than the contact surface of the outer plate LB 3. --.
Page 71 Automatic Transmission/Controls, Case Measure distance "e": Inner plate 2.1 mm thick Place measuring bridge 9313 on Outer plate 7.7 mm thick piston of plate brake and measure Outer plate 2.3 or 2.8 mm with depth gage to seal. thick* Outer plate 2.8 mm thick Shim 2.5-3.0-3.5...
Page 72 Automatic Transmission/Controls, Case 25.Insert 20.Insert clutch while turning brake-band guide. locating pins must engage until teeth engage. holes in the case. 21.Insert brake band such that is facing from assembly lock 1 (see 19). pressure unit Step 22.00 not insert axial bearing shims until...
Page 73 Automatic Transmission/Controls, Case Measure distance "a": Measure distance "b": Place seal on front cover. Place 9113 Place measuring bridge 9313 Special Tool on flange prepared face and, with depth gage, with depth gage, measure to seal. measure to clutch K 1 (e.g. 123.6 119.0 mm).
Page 74 Automatic Transmission/Controls, Case Select axial bearing, rotation 28.With a blob of grease, attach washer and shims such that spacer to support and place overall thickness is 3.8 mm. front cover with seal position. Tighten mounting bolts. Tightening torque: 13 NM (10 ftlb).
Page 75 Automatic Transmission/Controls, Case 3D.Insert circlip and position 32.Insert 0-ring.and install spacer right way round. centrifugal-force controller 33.Swing axial holder over centrifugal-force controller that holder engages groove controller shaft. Note: The spacer has been in use since approx. December, 1986. 31.Install helical gear and axial holder.
Page 76 Automatic Transmission/Controls, Case 36.Place secondary pump in position 34.Insert cover and install circlip. Then pull cover out so and tighten hex bolts. Tightening torque: 8 Nm that makes contact with (5.9 ftlb). circlip around entire circumference. 37.Recheck seating of axial holder and tighten new nut.
Page 77 Automatic Transmission/Controls, Case 38.Insert tube (arrowed) 4O.Push roller onto sprung linkage, tighten socket-head bolt. place plastic guide in position Tightening torque: 8 Nm and push into positioning holes. (5.9 ftlb). The oil tube is discontinued of '87 models. ~, \: .L 1 ,^ a, LL‘-...
Page 78 Automatic Transmission/Controls, Case 42.Install parking lock pawl, Use a depth gage to measure from expander spring and parking lock rotation ring to seal (e.g. gear. 15.3 mm). 43.Measure axial play "C" of output shaft (clutch K 2) and correct. Special Tool 9312 Rotation...
Page 79 Automatic Transmission/Controls, Case Use a depth gage to measure from case bearing face to inner race cylindrical roller bearing (e.g 15.9 ml). Example: 34.55 mm As-is (measured Distance "b" minus distance "a" bearing assembly) equals distance "C". 34.00 mm Specified (design distance) -_______-__...
Page 80 Automatic Transmission/Controls, Case 47.Install vacuum-control unit with holder and tighten socket-head bolts. Tightening torque: 8 Nm (5.9 ftlb). Place starter interlock switch in position slightly tighten mounting bolts (do not tighten fully). Place range selector lever in position such that carrier is fixed lever.
Page 81 Automatic Transmission/Controls, Case Note: 49.Bolt Special Tool 9316 to transmission case and insert Brake-band pistons with five brake band piston B 1 with different pressure pins marked with compression springs and Special grooves (arrowed) are available Tool 9320. Screw spindle down correct play...
Page 82 Automatic Transmission/Controls, Case 50.Insert circlip, relieve Special Tool 9316 and remove. 51.Measure and adjust play "L" brake band. Note: The thread of Special Tool 9320 has a 1 mm lead, which means that full turn equals 1 mm travel. Turn screw of Special Tool hand until...
Page 83 Automatic Transmission/Controls, Case 54.Install pressure pin with larger Tighten screw further with torque diameter toward brake band B 2. wrench, counting turns tightening to 5 Nm (2.3 ftlb). * -, .‘Vpq &q”:,, r” f.:;;.i,~ ;G> “+$+++oQ$&~ 9. ,+:: :’ 9 ,I ~~~&;;x&...
Page 84 Automatic Transmission/Controls, Case 58.Measure play "L" at brake band Note: B 2 and adjust: press brake band B 2 toward Pressure pins are available in 4 lengths correcting travel brake band piston at support (as arrowed) so that brake band brake band B 2.
Page 85 Automatic Transmission/Controls, Case The difference between the two 60.Insert brake band guide. measurements is the play "L". Adjust play "L" to 6...7 mm by changing pressure in brake band piston 59.Insert one-way valve and filler. 61.Insert temperature throttle push into duct until throttle...
Page 86 Automatic Transmission/Controls, Case 62.Install lower cover with back 64.Engage return spring. plate, in so doing, insert tube in casing bore. -- -* )‘, ‘, 65.Place leaf spring with holder position and tighten mounting bolts slightly (do not tighten 63.Insert combination bolts fully).
Page 87 Automatic Transmission/Controls, Case Note: 67.Insert combination bolts tighten to 8 Nm (5.9 ftlb). Holder must be properly pinned place. -8” ,qP-- Note length of bolts. The three I/-- arrowed bolts are only 50 mm long, the remaining 12 bolts are 55 mm long.
Page 88 Automatic Transmission/Controls, Case 71.Install pan with gasket, 69.Check clearance "a" between screw down mounting bolts locking piston and stop tighten to 8 Nm (5.9 ftlb). sprung linkage, adjust necessary. Use plastic clips adjust play to 0.4...1.0 mm with selector in "N" position. Plastic clips are available...
Page 89 Automatic Transmission/Controls, Case 72.Set range selector to "N" position, insert a holding made of 4 mm welding wire mm twist drill) through selector into hole in shift valve casing and tighten mounting bolts 8 Nm (5.9 ftlb). Remove holding pin. Note: Once the transmission has been...
Page 90 Automatic Transmission/Gears, Valve Body TOOLS Description Special Tool Remarks Pressure tester v 90 Hoses 9170 Adapters 9300/l Printed in Germany - VI I I, 1984 Checking Transmission Operation 38 - 101...
Page 91 Automatic Transmission/Gears, Valve Body CHECKING TRANSMISSION OPERATION B-Transmission Fluid Level Prior to making repairs on an automatic trans, mission, troubleshoot transmission as instructed below and with help from the following tests. The specified fluid level is extremely important for proper operation of an automatic transmission, so that following A - General Checks test must be carried out with great care.
Page 92 Automatic Transmission/Gears, Valve Body level in transmission will change with fluid After correcting level to specifications, temperature. Max. and min. marks on transparent operate brake pedal, leave selector lever in each tank are in reference to an ATF temperature position (R-N-D-N-R) several seconds...
Page 93 Automatic Transmission Gears, Adjustment 4.Set selector lever to "Cl", fully D - Test Drive depress gas pedal, transmission must reach the specified stall speed (see Technical Data, Take the vehicle a test drive page 30 - 0103). (only transmission not obviously damaged).
Page 94 Automatic Transmission/Gears, Control Checking Operation points in Shifting km/h TransmissionType TransmissionType A 28.02/05/08 A 28.01/04/07/12 km/h km/h km/h km/h Selector lever position Idle "D" 1-2-1 54...59 26u.22 58...64 28...24 Idle "D" 2-3-2 109...125 54...47 102...117 50...44 Idle "D" 3-4-3 177...197 122...107 190...211 131...115...
Page 95 Automatic Transm~ssion/Gears. Valve Body Pressure Test A pressure tester with up fo 25 bar pressure range This pressure test wll lndlcate any defects in the is required for measuring the operating pressure. hydraulic control system. The 10 bar pressure wswr is applted for modulatmg and governor...
Page 96: Checking Transmission Operation
Automatic Transmission/Gears, Valve Body Connections for modulating and governor pressures Connection for operating pressure Note: Do not let hoses hang through too much or rest on the exhaust svstem. 38 - 107 Checking Transmission Operation Printed in Germany VII, 1983 ITransmission Type A 28.01)
Page 97 Automatic Transmission/Gears, Control Modulating pressure, measuring Note: Modulating pressure, adjusting is essential to measure the modu- lating pressure and reset neces- l.Remove rubber cover from vacuum- control unit. sary, before testing any other pressures. When the modulating pressure is correctly set, the work- ing pressure...
Page 98 Automatic Transmission/Gears, Valve Body Measuring Governor 3. Lockplate must be pressed into nearest locking slot again after finishing adjust. Pressure ment. Since governor pressure is derived from operating pressure, operating pressure must 4. Recheck after finishing adjustment. be checked simultaneously or previously.
Page 99 Automatic Transmission/Gears, Regulation SPECIFIED PRESSURES IN BAR UP TO '86 MODELS Test Transmission Transmission Testing Conditions type pressure A 28.02/03/ A 28.01/04/07 05/06/08/09/11 4.4 t 0.05 4.0 + 0.05 Modulating ATF temperature approx. pressure* 8O"C, selector lever at "D" speed approx: 140 km/h vacuum line...
Page 100 Automatic Transmlsslon. Gears. Shafts Checking functioning Nomlnal pressures In bar as from Model ‘87 Test pressure Gearbox type Measuring conditions A 28.12/14/16 A 28.18 Modulation pressure’ 4.2 k 0.05 4.4 f 0.05 ATF temperature approx. 80X, Selector lever in position D, driving speed approx.
Page 101 Automatic Transmission/Gears, Valve Body TROUBLESHOOTING AUTOMATIC TRANSMISSION Note: If transmission oil is black and smells burnt or there is an unusual large amount of metal particles in oil pan, either repair or replace transmission. Condition: Transmission slips in all selector lever positions. Cause/Correction: 1.
Page 102 Automatic Transmission/Gears, Valve Body Condition: Transmission slips when moving off in 1st and 2nd gear, or moving off not possible in forward gear. Reverse gear is still good. Cause/Correction: 1. Service shift valve B 2. replacing shift valve housing if necessary. 2.
Page 103 Automatic Transmission/Gears, Valve Body Condition: After installation, transmission has no power flow or fails after a brief time of operation, Cause/Correction: Torque converter not installed according to instructions. Drive dogs do not engage accurately in drive gear of primary pump. Follow-up damage: Torque converter drive dogs and...
Page 104 Automatic Transmission/Gears, Valve Body Condition: Strong jolt when engaging selector lever in “D” and “R”. Cause/Correction: 1. Adjust idle speed and CO level to specifications. 2. Check modulating pressure, correcting if necessary 3. Check whether spring is installed underneath valve ball (5) in shift valve housing (see page 38 126).
Page 105 Automatic Transmission/Gears, Valve Body Condition: Strong jolt in downshift from 4th to 3rd gear. Cause/Correction: 1. Replace seal on release end of B 2 2. Replace brake band piston B 2 3. Pressure element of B 2 has turned; replace pressure element.
Page 106: Troubleshooting
Automatic Transmission/Gears, Valve Body No upshifts. Cause/Correction: 1. Check governor pressure. If there is no governor pressure reading, continue with point 2. If governor pressure is correct, continue with point 3. 2. Clean and service centrifugal governor. 3. Disassemble and clean shift valve housing. replacing if necessary.
Page 107 Automatic Transmission - Gears, Regulation Fault: No kickdown from 3rd to 2nd shifting points in partial load range too low Cause/remedy check gas and control pressure cable settings Fault: No kickdown downshifts Cause/remedy: l.Check fuse power supply to solenoid valve. Z.Remove solenoid valve.
Page 108 Automatic Transmission/Sears, Valve Body Condition: Automatic, unwanted downshifts outside of partial throttle downshift range, without operation of kickdown switch. Cause/Correction: 1. Remove kickdown solenoid valve. Check O-ring on solenoid valve for damage 2. Check whether kickdown switch sticks in pressed position, replacing if necessary.
Page 109 Automatic Transmission/Gears, Valve Body Condition: Selector lever cannot be engaged in “R” and “P”. Cause/Correction: a) With engine running b) With engine stopped 1. a) Clean and service centrifugal governor 2. b) Service blocking piston in lower cover. Condition: Engine cannot be started with selector lever in “P” and “N”. Cause/Correction: 1.
Page 110 Automatic Transmission/Gears, Valve Body Condition: 1st and reverse gears too loud. Cause/Correction: 1. Replace front gear set depending on findings. Note: First and reverse gears are louder than the other gears because of the ratio. A different car should be used for comparison. Condition: 3rd gear too loud.
Page 111 Automatic Transmission/Gears, Valve Body Condition: Invisible oil loss (leak cannot be seen on outside) in conjunction with smoke in exhaust. Cause/Correction: Diaphragm in vacuum box is defective. ATF drawn in by engine via vacuum line. 1. Replace vacuum box. Condition: Oil lost between torque converter and primary pump...
Page 112 Automatic Transmission/Gears, Valve Body Condition: Rattling noise at engine speed of 1500 rpm in all selector lever positions, except “R” Cause/Correction: Plates of reverse gear brake swinging in transmission case. 1. Replace inner plates of reverse gear brake B 3; adjust play to smallest value.
Page 113: Removing And Installing Shift Valve Casing
Automatic Transmission/Gears, Control REMOVING AND INSTALLING SHIFT VALVE CASING Removing l.Remove drain plug and drain ATF. 3.Unscrew mounting bolts and remove shift valve casing. Installing Z.Remove ATF pan by disconnecting l.Ensure that plastic poppet valve breather holes ATF reservoir and chip screen shift valve...
Page 114 Automatic Transmission/Gears, Control 4.Install ATF pan with gasket 2.Place shift valve casing position, range selector valve tighten mounting bolts. must engage carrier. Tightening torque: 8 Nm (5.9 ftlb). 3.Insert mounting bolts 5.Screw in drain plug with tighten. Tightening torque: 8 Nm sealing ring and tighten.
Page 115 Automatic Transmission/Gears, Control 2.Place shift valve casing 4.Install ATF pan with gasket position, range selector valve tighten mounting bolts. must engage carrier. Tightening torque: 8 Nm (5.9 ftlb). 3.Insert mounting bolts 5.Screw in drain plug with tighten. Tightening torque: 8 Nm sealing ring and tighten.
Page 116 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING SHIFT VALVE HOUSING 5 678 :-y; I;?‘& & .cb , *i 4 ; I --& .F$;: >.,’ ‘)$J -. : ,, ,i’L r* % -i ,s_ i ? *c-* c=l*A4 ‘*. I_ ..’ [,F, ,i$ ‘w- hi ,-.- .
Page 117 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING SHIFTVALVE HOUSING ..-.--_ 38.126 Disassembling and Assembling Shift Valve Housing Printed in Germany...
Page 118 Automatic Transmission/Gears, Valve Body Special Qtv. Note When: Description Installing Instructions Removing Install conical Valve ball spring with large (5.5 mm dia.) diameter end facing down underneath ball no. 5 Install in Plastic valve correct position, flight without do not mix up bore) with valve without...
Page 119 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING SHIFT VALVE HOUSING Disassembling Note: Absolute cleanliness is essential for any work on the shift valve housing. If at all possible work should be done on a plastic lined work- bench (leather sheets would be especially suitable).
Page 120 Automatic Transmission/Gears, Valve Body Assembling 4. Place pick-up housing on shift valve housing. 1. Place all balls and valves in shift valve housing (see layout drawing). 5. Hold shift valve housing and pick-up housing together and turn both around. 2. Install lubricating valve, modulating pressure valve and vent valve K 1 in pick- 6.
Page 121 Automatic Transmission/Gears, Control DISASSEMBLING AND ASSEMBLING SHIFT VALVE CASING ('87 MODELS ONWARD) Printed in Germany - XVI,1987 Disassembling and Assembling 38 - 130 a Shift Valve Casing ('87 Models Onward)
Page 122 Automatic Transmission/Gears, Control DI 'SASSEMBLING AND ASSEMBLING SHIFT VALVE CASING ('87 MODELS ONWARD) ’ I I I ---*d.,r Q& 1’: qy,” ,j~==-=.q, a>) “7;,,=<i ./,>,A$ Printed in Germany 38 - 130 b Disassembling and Assembling Shift Valve Casing ('87 Models Onward)
Page 123 Automatic Transmission/Gears, Control Note When: Designation ?emoving Installing l.., Valve ball Insert taper spring with (dia. 5.5 mm) large diameter downward beneath ball No. 5. Plastic valve Insert right way round, (light, withou do not mix up with valve bore) with bore Throttle...
Page 124 Automatic Transmission/Gears, Control NOTES FOR DISASSEMBLY AND ASSEMBLY Disassembling 2.Remove both mounting screws Note: (arrowed). is essential to maintain absolute cleanliness during work on the shift valve casing. possible, spread a plastic sheet the workbench beneath the parts (moleskin cloths are particularly suitable).
Page 125 Automatic Transmission/Gears, Control Assembling 3.Carefully place back plate shift valve casing and check that valve ball (arrowed) is in its l.Place valve balls and valves installation position. shift valve casing (see exploded drawing). 2.Install lubricating-pressure valve, overpressure modulating valve and bleed valve Kl in sensor...
Page 126 Automatic Transmission/Gears, Control Note: Tighten screws so that housing casing can still be moved against each other. 7.Insert plastic valve (yellow) in casing with bore and chip screen right way round. A = Plastic valve B = Chip screen Printed in Germany 38 - 130 f Disassembling...
Page 127 Automatic Transmission/Gears, Valve Body REMOVING AND INSTALLING LOWER COVER Installing Removing 1. Check for proper seating of temperature 1. Remove shift valve housing. orifice, plastic valve, filler and oil deflector. 2. Remove ATF filter. 3. Remove holder and leaf spring. .m-.
Page 128 Automatic Transmission/Gears, Valve Body 2. Mount lower cover, guiding oil tube into bore. 3. Install combination bolts, but do not tighten (tighten bolts with 8 Nm/6 ftlb only after installing the shift valve housing) 4. Mount leaf spring with holder and install bolt but do not tighten (tighten bolt with...
Page 129: Disassembling And Assembling Lower Cover
Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING LOWER COVER .A’ .‘---... we’ -,~_/ ,’ f’ 38-133 Disassembling and Assembling Printed in Germany VI I I, 1984 Lower Cover...
Page 130 Automatic Transmission/Gears, Valve Body Description Note When: Special Removing Installing Instructions Oil tube Injector Squeeze tabs Install in correct together and position remove Torque: Bolt 8 Nm/6 ftlb Cover Replace, Gasket if necessary Transfer plate Filter screen Valve Position correctly, check for tight Position correctly...
Page 131 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING LOWER COVER Note: Assembling Absolute cleanliness is essential for any work on shift valve housing and lower cover. 1. Install shift valve secondary pump with Work should be performed with a plastic liner spring and plug, and secure with holder.
Page 132 Automatic Transmission/Gears, Valve Body 7. Insert injector in correct position until 3. Install valve and filter screens in correct both tabs (arrows) engage. position. 4. Place transfer plate and gasket on lower cover. 5. Align gasket with transfer plate by inserting two bolts.
Page 133: Replacing Atf And Filter
Automatic Transmission/Gears, Valve Body TOOLS -;c’ Description Special Tool Remarks Filler Commercially available, e. g. Dresser-Wayne Model 3009 Printed in Germany . VIII, 1984 Replacing ATF and Filter 38-137...
Page 134 Automatic Transmission - Gears, Regulation AFT AND FILTER, CHANGING Filling Capacities Turn crankshaft until the con- verter drain plug is visible After drainage approx. can be removed. After change approx. oil: Types ATF Dexron B - sperm-oil free The ATF and the filer must be changed every 40,000...
Page 135 Automatic Transmission - Gears, Regulation Install pan with gasket yF ~ torque retaining bolts with 8 Nm (8.7 ftlb). ..r; Screw in plugs with new seals tighten with 14 Nm (10.2 ftlb). Refilling with Before starting the engine, a filler to pump most of the ATF (approx.
Page 136 Automatic Transmission - Gears, Regulation Up to 85 models 86 models onward 1 = max. at 80°C ATF temperature 2 = min. at 80°C ATF temperature 3 = max. at ZO-30°C ATF temperature XII, 1986 - Printed in Germany 38 - 140 ATF and Filter, Changing...
Page 137: Flushing Atf Cooler And Lines
Automatic Transmission/Gears, Valve Body FLUSHING ATF COOLER AND LINES Note: 3. Attach extra hose from ATF charger (see Workshop Equipment Group of Special If ATF smells burnt and there are metal Tool Catalog) on return line and flush particles, sludge or liner abrasion in oil pan, cooler as well as lines with the charger.
Page 138 Automatic Transmission/Gears, Valve Body REMOVING AND INSTALLING GOVERNOR Removing 1. Loosen intermediate muffler shield and 4. Loosen nut for axial holder. push aside as far as possible. 2. Unlock plug for starter locking and backup light switch by turning up white plastic ring in direction of arrow.
Page 139 Automatic Transmission/Gears, Valve Body 6. Pull out governor. Installing 1. Guide in governor. Note: Absolute cleanliness is necessary for installa- tion of governor. If necessary, cover area of Note: governor installation with lint free cloths. Axial holder has been installed correctly when slot is horizontal (position...
Page 140 Automatic Transmission/Gears, Valve Body Checking Governor Move centrifugal weight “A” and at same time check movement of governor valve in openings (arrows). Note: It should be possible to move governor valve easily. If necessary, wash governor and dry thoroughly with compressed air. Printed in Germany - VI I I, 1984 Checking Governor...
Page 141 Automatic Transmission/Gears, Valve Body REMOVING AND INSTALLING VACUUM MODULATOR Removing 1. Loosen intermediate muffler shield and 2. Adjust modulating pressure (see page push aside as far as possible. 38 - 108). 2. Pull off vacuum hose on vacuum modulator. 3. Remove socket head screws and remove with holder.
Page 142 Automatic Transmission/Gears, Valve Body TOOLS Description Special Tool Remarks Guiding sleeve 9319 Centering pins 9321 Printed in Germany VIII, 1984 38. 149 Removing and Installing Primary Pump...
Page 143 Automatic Transmission/Gears, Valve Body REMOVING AND INSTALLING PRIMARY PUMP 13 14 III-L a?@&*!“: -“i’ ’ L .-.-.-.-.-.-.-.-.-.-.-.-. A;-‘- Printed in Germany 38-150 Removing and Installing Primary Pump...
Page 144: Removing And Installing Primary Pump
Automatic Transmission/Gears, Control Note When: Description Removing Installing Thrust washer Teflon ring Replace, install with grease. Circlip Spring plate Insert right way round Compression spring Piston Insert right way round Sealing ring Sealing must face Nith toward cover Sealing ring with iex bolt Tightening...
Page 145 Automatic Transmission/Gears, Control NOTES FOR REMOVING AND INSTALLING Removi Note: is not necessary to disassemble the transmission to remove or install the primary pump. l.Remove transmission. Z.Remove front converter casing converter. 3.Unscrew mounting bolts front 6.Unscrew mounting bolts and remove transmission cover.
Page 146 Automatic Transmission/Gears, Valve Body 2. Lubricate both pump gears with ATF and install in pump body, whereby the large gear must be installed that the chamfer (arrow) faces bearing sleeve. 5. Apply Special Tool 9319 on front cover and coat sliding surfaces with ATF. 6.
Page 147 Automatic Transmission/Gears, Valve Bodv 8. Install return springs and diaphragm spring. 9. Slide circlip over Special Tool 9319, hold circlip down and pull off special tool. 10. Push down on diaphragm spring with circlip until circlip engages in its groove. 11.
Page 148 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING SECONDARY PUMP 3 ‘-, 5 ‘pc .- ./*- /.-* /.-’ Printed inGermany VIII, 1984 Disassembling and Assembling 38-155 Secondary Pump...
Page 149 Automatic Transmission/Gears, Valve Body Note When: Special Description Qty. Installing Instructions Removing Replace if O-ring necessary. Coat with ATF Transfer plate Coat with ATF Gear (driven) Coat with ATF; Gear (driving) drive dog must engage in groove ’ Circlip Cover Spring Replace, coat O-ring...
Page 150 Automatic Transmission/Gears, Valve Body TOOLS Special Tool Remarks Description 9314 Assembly stand Printed in Germany VI I I, 1984 Disassembling and Assembling 38.157 Gear Assembly...
Page 151 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING GEAR ASSEMBLY US!, ---Y ‘I -- ; L- -& ,$rz 2 _.-- _r~.:d .-.-.-.-.-,-.-.-.-.-.-.-.A 10 9 q -\ i *ld r .-. -.-. -.-.- .-.-.-._._._. . 11 12 & ;$$i~ $lL~ .\, -~,e.,u~$Z, -+I,.- 'j&j G,.
Page 152 Automatic Transmission/Gears, Valve Body Special Note When: Description Qty. Instructions Installing Removing Lnstall only after Clutch K 1 gear assembly is in case Axial bearing Thrust washer Note thickness Redetermine Shim thickness for reinstalla- necessary tion Remove with a Check for correct Snap ring suitable screw- driver...
Page 153 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING GEAR ASSEMBLY Disassembling I, Clamp Special Tool 9314 in a vise on both 3. Take off parts separately. surfaces with plate facing up and mount gear assembly with drive shaft facing up. 4. Remove snap ring and take inner plate carrier with one-way clutch out of connecting...
Page 154 Automatic Transmission/Gears, Valve Body 2. Mount sun gear and install axial bearing. CT-v-- ‘7 ” ;’ ( :, 5 L,~ ,_),. n ‘I, YJ.a ?? .--::,,. ,, ‘, *r .‘: ,,,& ‘, b +k+++~ ‘\ 6. Install front gear set and secure with snap 3.
Page 155 Automatic Transmission/Gears, Valve Body 8. Install split radial bearing on output shaft 10. Take gear assembly off of Special Tool with a small amount of grease. 9314 and install axial bearing on drive shaft with a small amount of grease. I ,-.
Page 156 Automatic Transmission/Gears, Valve Body TOOLS Description Special Tool Remarks Lockplate 9322 Sixteen (16) Feeler blade gauge Standard tool Printed in Germany VIII, 1984 Disassembling and Assembling 38-163 One-wav Clutch...
Page 157 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING ONE-WAY CLUTCH -\ , 1 .-* -.-• 38-164 Disassembling and Assembling Printed in Germany One-way Clutch...
Page 158: Disassembling And Assembling One-Way Clutch
Automatic Transmission/Gears, Valve Body Description Qty. Note When: Special Removing Installing Instructions Snap ring Check for correct fit Connecting carrier Shim Redetermine thickness, if necessary Support Position correctly One-way clutch Use Special inner race Tool 9322 Shim Roller cage 1 ’ Cyl.
Page 159 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING ONE-WAY CLUTCH Disassembling I. Place thrust washer and O-ring on inner 1. Remove snap ring and lift inner plate carrier plate carrier. K 2 with one-way clutch out of connecting carrier. 2. Install cylindrical rollers in roller cage.
Page 160 Automatic Transmission/Gears, Valve Body 3. Place outer race of one-way clutch on inner plate carrier and install roller cage in correct oosition. 6. Remove Special Tool 9322. 7. Install shim. 4. Push cylindrical rollers against springs and apply Special Tool 9322 with bend facing out.
Page 161 Automatic Transmission/Gears, Valve Body 8. Install support that pin engages in bore (arrow) of one-way clutch outer race. /’ p4* “, (_ -. ‘- . . . b, ; : me.;:. : ,. I _ ‘1 ‘-4 ‘* Checking Adjusting One-wav Clutch Axial...
Page 162 Automatic Transmission/Gears, Valve Body TOOLS ff+-+----+b .-. 1 !’ ,’ ;,“- j \ . ../z ,,/’ .- 1’ ??+- Special Tool Remarks Description 9315 Assembly tool 9317 Assembly sleeve 9318 Assembly sleeve Standard tool Feeler blade gauge Printed in Germany VIII, 1984 38 - 169...
Page 163 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING CLUTCH L .-.-.m.-.-.-.-.- .m.m.s. Printed in Germany 38-170 Disassembling and Assembling Clutch...
Page 164 Automatic Transmission/Gears, Valve Body Iescription Qty, Note When: Special Removing Installing Instructions ;nap ring Redetermine thickness, if necessary Iuter plate Check for burnt 4.5 or 5.0 mm spots and bendil thick (optiona “!3 to adjust play) nner plate Check for burnt 2.1 mm thick) spots and wear.
Page 165 Automatic Transmission/Gears, Valve Body Special Note When: Description Qty. Instructions Removing Installing Install with Piston Special Tools 9317 and 9318 Position correctlv. Seal coat with ATF ” Position correctly. Seal coat with ATF ’ 13 Plate carrier Printed in Germany Disassembling and Assembling 38.
Page 166 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING CLUTCH Disassembling 1. Apply Special Tool 9315 on diaphragm spring and tighten until snap ring can be removed. 2. Apply Special Tools 9318 and 9317 in outer plate carrier. 3. Install piston carefully and press into outer plate carrier without canting.
Page 167 Automatic Transmission/Gears, Valve Body 4. Install springs in piston and place on Checking Play (0.7 to 1.2 mm) of Clutch: diaphragm spring, whereby each spring must be centered by a guide pin. 1. Push up snap ring around entire periphery with a suitable screwdriver.
Page 168 Automatic Transmission/Gears, Valve Body Note: Play “A” can be adjusted with a snap ring which is available in 3 thicknesses (2.0 / 2.5 / 3.0 mm). However, if the specified play cannot be reached with snap rings, the center outer plates must also be used for adjusting.
Page 169 Automatic Transmission/Gears, Valve Body TOOLS Description Special Tool Remarks Assembly tool 9315 Assembly sleeve 9317 Feeler blade gauge Standard tool Printed in Germany VI I I, 1984 Disassembling and Assembling Clutch...
Page 170 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING CLUTCH *-‘-7 r-9-l-l . ,. . ., 38-178 Disassembling and Assembling Printed in Germany Clutch...
Page 171 Automatic Transmission/Gears, Valve Body Description Qty. Note When: Special Removing Installing Instructions Snap ring Redetermine thickness if necessary Outer mate Check for burnt 1.5or5.0mm spots and bending thick :optional adjust play) Inner plate Check for burnt (2.1 mm thick) spots and wear. Replace if thickness is less...
Page 172 Automatic Transmission/Gears, Valve Body Description ~~~~ Note When: Special I Removing Instal!ing Instructions Seal Position correctly, coat with ATF Sea I Coat with ATF, must not turn on its own Plate Carrie1 Disassembling and Assembling Pttnted iv Germanv Clutch...
Page 173 Automatic Transmission/Gears, Valve Body DISASSEMBLING AND ASSEMBLING CLUTCH Disassembling 1. Apply Special Tool 9315 on diaphragm spring and tighten until snap ring can be removed. 2. Install seal in piston that sealing lip faces down (direction of arrow). 2. Remove diaphragm spring and springs Note: The quantity...
Page 174 Automatic Transmission/Gears, Valve Body 4. Install piston in plate carrier by turning 6. Apply and tighten Special Tool 9315. slightly. Do not cant the piston. 7. Install snap ring. 8. Assemble set of plates as shown in layout drawing and install in plate carrier. Note: Place new inner plates in ATF about 1 hour before installing.
Page 175 Automatic Transmission/Gears, Valve Body 2. Check play “A” with a feeler gauge blade. Note: Play “A” can be adjusted with a snap ring which is available in 3 thicknesses (2.0 / 2.5 / 3.0 mm). However, if specified play cannot be reached with snap rings, the center outer plates must also be used for adjusting.
Page 176 Differential/Transaxle System TOOLS Description Special Tool Remarks Holder 9216 Centering 9321 Puller Standard tool Pressing in tool Made locally (45 x 5 x 40 mm steel pipe with welded cover and 11 mm dia. bore) Standard iool Depth gauge Printed in Germany VI I I, 1984 Removing and Installing...
Page 177 DifferentiaI/Transaxle System REMOVING AND INSTALLING FINAL DRIVE r'-'- .-.- .-.-. - .-.-.-. - .-.-. -.-.- 14x3- ,, /i,r '2: !j&-; \- 1, , ’ ( -; ! if<>, 18 16 14 13 39-102 Removing and Installing Final Drive Printed in Germany...
Page 178 Differential, Transaxle System Note when Description Qty. Removing Installing Bolt Torque: 49 Nm / 33 ftlb Washer Holder Collar nut Torque: 46 Nm / 33 ftlb Torque: 46 Nm/ 33ftlb Washer Bolt Torque: 46 Nm / 33 ftlb Washer Final drive O-Ring Replace, coat with ATF, check for correct fit...
Page 179 Differe”tial/Tra”saxle System Special Note When: Description Instructions Removing Installing If necessary. If necessary, Bearing assembly pull out with press in with with drive pinion suitable puller locally made tool Note quantity Redetermine, Shim and thickness if necessary reinstallation Replace. O-ring coat with ATF Replace, O-ring...
Page 180 Differential/Transaxle System REMOVING AND INSTALLING FINAL DRIVE Removing Installing 1. Remove transmission. 1. Install quantity of shims noted during removal or shims of redetermined thickness 2. Mount transmission on assembly stand with and bearing assembly on drive pinion. Special Tool 9216 and drain final drive oil. 3.
Page 181 Differential, Transaxle System 2. Tighten flange nut for drive pinion to speci- fied torque and lock by upsetting the flange. 39-106 Removing and InstallIng flnal drive Printed in Germany - XXXI. 1993...
Page 182 Differential/Transaxle System TOOLS Remarks Description Special Tool Pressure pad 9147 From P 254 Printed in Germanv - VI I I, 1984 Disassembling and Assembling Final Drive 39.107...
Page 183 DifferentiaI/Transaxle System DISASSEMBLING AND ASSEMBLING FINAL DRIVE J ,‘,~ y; 7 l5 “Jr; ;‘.’ I 4/ , \+ 2;’ -X.- \‘- 4,’ Y -.. I -_ I rC Printed in Germany Disassembling and Assembling Final Drive 39-108...
Page 184 Differential/Transaxle System Description Qty. Note When: Special Removing Installing Instructions Torque: Bolt 23 Nm/17 ftlb Washer Holder Cover Replace Gasket Torque: Plug 22 Nm/17 ftlb Torque: Plug (with magnet) 22 Nmfl7 ftlb Shield Bolt Torque: 46 Nm/33 ftlb Joint flange Bolt Torque: 23 Nmll7...
Page 185 Differential/Transaxle System Special ‘Jo. Description Qty. Note When: Removing Installing instructions Shim Note quantity Redetermine, and thickness if necessary on each side for reinstallation Drive out with a Drive in with Seal suitable screw- Special Tool driver 9147 Mark for Install in same Tapered roller reinstallation...
Page 186 Differential/Transaxle System DISASSEMBLING AND ASSEMBLING FINAL DRIVE Disassembling Assembling 1. Install shield 1. Clamp final drive in a vise with a suitable fixture. .- - ‘- _ L L-, :’ fp+-ff?g-.. f I ,s$;, , ?’ .- I ,- *! :t I ’...
Page 187 Differential/Transaxle System ~~.__ _---- ‘I-. -~ .?q : \ .) ‘i’ ,,:; I..-:. I#-9 ‘i f.’ 2’ & Remarks Special Tool Description P 263 Pressure pad Standard tool Puller P 264 b Pressure pad 39 - 113 Printed in Germany - VI I I, 1984 Disassembling and Assembling Differential...
Page 188: Disassembling And Assembling Differential
Differential/Transaxle System DISASSEMBLING AND ASSEMBLING DIFFERENTIAL &Y ’ CY ‘<$j? .< \ c ,, z F” ’ c 1 (It ” $ 9’ = .- 13 12 9 11 1 lb11 Disassembling and Assembling Differential Printed in Germanv...
Page 189 DifferentiaI/Transaxle System Description Qty. Note When: Special Removing installing Instructions Tapered roller Pull off with Drive on with bearing inner race a suitable puller Special Tool and Special P 264 b Tool P 263 Circlip Magnet carrier plate ’ Lockplate Replace Bolt Threads must...
Page 190 DifferentiaI/Transaxle System Note When: Special Description Qty. Instructions Removing Installing Coat oval Large differential surface with gear MoS, paste. Replace only in pairs Threaded piece Differential case * Modified needle-bearing mount as from Model ‘86. The spacer sleeve is no longer required thanks to the new needle-roller assembly.
Page 191 Differential/Transaxle System DISASSEMBLING AND ASSEMBLING DIFFERENTIAL 2. Coat oval surface of differential gears with Disassembling MoS, paste. 1. Pull off tapered roller bearing inner race 3. Install large differential gears with press- with.a suitable puller and Special Tool fit threaded plates through large opening P 263.
Page 192 Differential/Transaxle System 4. Install small differential gears between large 6. Drive in differential pins to correct differential gears and turn, until bores of position and lock with key. gears are aligned with bores in case. ._- --- r----‘m I’-* ‘,.+ .~.
Page 193 DifferentiaI/Transaxle System TOOLS I+@@& .yh-? A ?,* ,.~: 1.. r-7’ PA!!@@ < -f--b ,/.~ ----. /‘“*ah Description Special Tool Puller e. g. Kukko, size 2 Depth gauge Standard tool Printed in Germany - VIII, 1984 Disassembling and Assembling Bearing Assembly...
Page 194 Differential/Transaxle System DISASSEMBLING AND ASSEMBLING BEARING ASSEMBLY +Y , ‘p) ? \‘.~ \,x3 ?. \a Printed in Germany 39-120 Disassembling and Assembling Bearing Assembly...
Page 195 Differential/Transaxle System Description Qty. Note When: Special Removing Installing Instructions Bearing flange For replacements only available as complete part (positions 1 to 4) Tapered roller Heat to approx. bearing inner race 120 “C/250 and install Adjusting ring Tapered roller Heat to approx. bearing inner race 120 “C/250 and install...
Page 196 Differential/Transaxle System DISASSEMBLING AND ASSEMBLING BEARING ASSEMBLY Assembling Disassembling 1. Press out pinion with a piece of suitable pipe. Note: Bearing flange is only available as a complete unit (with tapered roller bearings and adjusting ring) for replacements. 1. Heat tapered roller bearing inner races to approx.
Page 197 Differential/Transaxle System 3. Lubricate both tapered roller bearings with Use a depth gauge to measure distance from final drive oil through oil feed bore after tapered roller bearing surface to tearing installation. flange surface (for example: 34.55 mm). ,// / (‘42 Since the design calls for a distance of only I / /f 9 ,,( $7 34 + 0.05 mm, a shim 0.55 mm thick has to...
Page 198: Adjusting Drive Pinion And Ring Gear
Differential/Transaxle System TOOLS Description Special Tool Remarks Master gauge VW 385/l Centering plates VW 385/4 Master plunger VW 385114 gauge Dial extension (30 mm) 9323 gauge Adjusting VW 385130 Dial gauge Standard, 3 mm range Dial gauge Standard, 10 mm range Feeler gauge Standard, 0.05 to 1 .O mm...
Page 199 Differential/Transaxle System Recommended Sequence Adjustment Pinion/Ring Gear If drive pinion and ring gear have to be adjusted, the following sequence of procedures would be most economical. 1. Determine total shim thickness “Sges” (S, plus S2) for specified preload of tapered roller bearing/differential.
Page 200 Differential/Transaxle System ADJUSTING DRIVE PINION AND RING GEAR General Information Accurate adjustments of the pinion and ring gear are immensely important for the service life and smooth running of the final drive. This is why pinions and ring gears are paired during manufacture and checked in special machines for tooth pattern and quietness...
Page 201 Differential/Transaxle System Changes Drive Pinion/Ring Gear Since about January of 1984 manufacturing uses optionally drive pinions/ring gears, on which a DM value (e.g. DM 75) is recorded instead of deviation “r” (N). Since this DM value is equal to adjusting distance E (R, + r), the adjusting distance does not have to be figured out for these drive pinions/ring...
Page 202 DifferentiaI/Transaxle System Changes Drive Pinions/Ring Gears In the near future there will be drive pinions/ring gears with the following adjusting information. Design distance 74.70 mm = Adjusting distance Deviation = Adjusting distance (R, + r), e. g. 75.05 mm Pair number (three digits: 001 999) Backlash Note:...
Page 203 DifferentiaI/TransaxIe System ADJUSTING PINION Pinion/Ring Gear Marked “N” Pinion;Ring Gear Marked ” D M ” On these drive pinion/ring gear sets adjusting On these drive pinion/ring gear sets “DM” distance “E” is calculated from known design is adjusting distance “E” distance “R,”...
Page 204 Differential/Transaxle System 1. Install bearing assembly with shims and 8. Install second side bearing cover without tighten collared nut to 380 Nm/275 ftlb. O-ring and secure with two bolts. 2. Install final drive case (without shims) 9. Pull out centering plate of master gauge and tighten all bolts or nuts to 46 Nm/ with the spindle that master gauge can...
Page 205 DifferentiallTransaxle System Example: Note: DM=E 75.00 mm The measured value will always deviate from 5.00 mm the set distance in clockwise direction (small needle of dial gauge will be between 80.00 mm adjustment 1 and 2). i. e. when adjusting the dial gauge master gauge with 1 mm preload the value deviating...
Page 206 Differential/Transaxle System ADJUSTING RING GEAR (Sges) 5. Check gap between transmission case 1. Clamp final drive case in a vise, using a and side transmission cover with a feeler gauge, A = L-iron bar 6. Calculate shim thickness Sges. Sges. = gap - 0.30 mm (bearing preload) 2.
Page 207 Differential/Transaxle System ADJUSTING BACKLASH 6. Engage parking lock. 1. Place shims determined for pinion adjust- ment between transmission case and final drive case. Install final drive case and 7. Turn rinq oear carefully by hand against tighten all mounting bolts to specified stop and set dial gauge to zero.
Page 208 Differential/Transaxle System DETERMINATION OF SHIMS S, AND Sz Measured backlash must be brought to value Determining Shim specified by manufacturer of pinion/ring Thickness (Opposite Ring Gear) gear by splitting total shim thickness Sges. S2 = Sges -S, Backlash required is stamped on ring gear. Adjusted backlash value could be less by 0.05 mm, but must never be greater than the...
Page 209 Differential/Transaxle System 2. Measure backlash and, if necessary, change shims S, and Sz again until specified play is reached. 3. Check backlash at four places on periphery. turning ring gear by 90” each time. Measurements must not deviate from each other by more than 0.05 mm.
Page 210: Disassembling And Assembling Central Tube
Differential/Transaxle System DISASSEMBLING AND ASSEMBLING CENTRAL TUBE Printed in Germany - VI I I, 1984 Disassembling and Assembling 39 -137 Central Tube...
Page 211 Differential,transaxiesystem Nite when: Designation Qty. Removing Replacing Pan-head screw Tighten only after driver plate (5) has been fitted to flywheel. Tightening torque: 80 Nm Circlip* Sleeve’ Shim’ Driverplate Pan-head Torque: 20 Nm Spring washer Hex bolt Torque: 45 Nm Spring washer Clutch housing Cover Sleeve...
Page 212: Checking Central Tube
Differential/Transaxle System Checking Central Tube 3. Small corrections can be made by Note: tapping face of central shaft with plastic Replace entire central tube with shaft and hammer. bearings, if bearings and/or shaft are damaged. There are no replacement parts available, 1.
Page 213 Differential/Transaxle System Adjusting Drive Plate To avoid axial pressure on crankshaft and crankshaft thrust bearings, the connections between flywheel and drive plate (distance X) must be checked and adjusted after replace- ment of engine, flywheel or central tube. This adjustment is not necessary after replacement of transmission or transmission...
Page 214 Differential/Transaxle System Determining Distance “X” Example: Measured value 52.5 mm Gauge thickness - 40.0 mm 1. Crankshaft must contact thrust bearing toward the rear. Use a lever to press Distance “A” 12.5 mm flywheel in direction of transmission, until axial play of crankshaft is eliminated.
Page 215 Differential/Transaxle System Note: Mark thickness of gauge used for measuring. Example: 45.4 mm Measured value - 40.0 mm Gauge thickness 5.4 mm Distance B Determine distance “X” X = A - B + 0.3 mm preload 12.5 mm 5.4 mm 7.1 mm Preload 0.3 mm...
Page 216 Diffarantiil, transaxle system PSD diagnosis / Troubleshooting PSD = Electronically controlled Porsche limited-slip differential D39 - 201 PSD diagnosis/Troubleshooting Printed in Germany - XXXV, 1995...
Page 217 Differential, transaxle system Contents Test point Title Page PSD layout ..__._.._____...__.......,..,,,,..,,,,..,..,,,..,,..,,..,,.,,,..,.,,,,. D39-202a Component layout _____..__..__._.._..,..,,,..,,,,..,,,..,,,,..,,,,..,,,..,,,,,,..,,,,. D39-202b PSD - fauit display I troubleshooting procedure __,__,,,,..,,,,..,..,,,..,... D39-202c Bleeding condition of lock control .,,..,,._..._..___........,,.., D39-202d (Re-bleeding lock operating hydraulics I point 2 on P. D39-202d) Measuring plate wear of controlled limited-slip differential...
Page 218 Differential, transaxle system layout 5 - Lock solenoid valve* 1 - ABS I PSD control unit 6 - Pressure reservoir 2 - Lateral acceleration sensor 7 - Supply tank* 3 - Slave cylinder, transverse lock - Wheel speed sensor 3a- Pilot pressure valve in lock hydraulics 4 - Pressure pump with pressure warning switch”...
Page 219 Differential, transaxle system Component layout Lock hydraulics ABS I PSD control unit The control unit is located in the driver’s foot- The lock hydraulics is accessible in the let% well - near the A-pillar - above the front cover hand rear wheel housing afler removal of the opening handle, wheel housing cover.
Page 220 Differential, transaxle system PSD - Fault display / Troubleshooting procedure Troubleshooting procedure Fault display Read out the DTC memory with system tester If the ABWPSD control unit detects a fault in 9288 and remedy the fautt if necessary. the electronically controlled limited-slip dif- This is described on Page 039-223 ff.
Page 221 Differential, transaxle system Bleeding hydraulics of Porsche controlled limited-slip differential (PSD) Preparatory work: Remove rear left inner fender. Connect bleeding device to PSD hydraulic reservoir Disconnect vent line (if present). Build up bleed pressure (approx. 1.5 - 2.0 bar). 1. Bleeding the pressure reservoir.
Page 222 Differential, transaxle system Check level in the reservoir. The fluid must be approx. I cm above the step in the reservoir body or between the markings (with the pressure reservoir charged). the plate wear on the controlled-slip differential Measuring Note The wear dimension can be determined only by means of the measuring cylinder - special...
Page 223 Differential, Transaxle System Checking locking torque (friction coefficient) of transverse lock Tools I .183-D D39 - 203 PSD-Diagnosis I Troubleshooting Printed in Germany - XXVII, 1991...
Page 224 Differential, Transaxle System Special tool Explanation Pressure gauge 9509 000.721.950.90 High-pressure measuring line 9509/l 000.721.950.91 Ring flange 999.215.027.02 Banjo bolt 930.110.547.00 shorten threads by approx. 4 mm Seal NO138112 2 PC. Union 950913 000.721.950.93 Torque adapter plate 951 O/l 000.721.951 .Ol 9509/4 000.721.950.94 1 pc.
Page 225 Differential, Transaxle System Checking locking torque (friction coefficient) of transverse lock Important notes Check with cold transmission. Parking brake released, no gear engaged. When checking the locking torque, it is not the rotating torque (starting torque) but rather the breakaway torque that is measured. For this reason, self-disengaging torque wrenches must be used.
Page 226 Differential, Transaxle System Procedure Execution 1 Notes 2. Prepare vehicle for transverse lock measurement. Proceed as follows: - Remove rear left-hand brake caliper. Remove rear left-hand brake caliper Place the support block (arrow) into the brake (do not open hydraulic brake system) caliper, replacing the brake disc.
Page 227 Differential, Transaxle System Procedure Execution I Notes ~~~~~~~~~ - Connect ring flange (No. 3) to measuring line (No. 2). Proceed by fitting this assembly, complete with banjo bolt, seals and fitting (Nos. 4, 5 and 6). to the transverse lock slave cylinder, replacing the bleeder valve.
Page 228 Differential, Transaxle System Execution / Notes - Connect high-pressure measuring line (No. 2) to pressure gauge (cf. arrow) and suspend pressure gauge (No. 1) in rear left-hand wheel housing area so that it may be read off easily. Bleed pressure gauge by connecting the bleeding device to the PSD reservoir.
Page 229 Differential, Transaxle System Procedure Execution I Notes 3. Perf. transverse lock measurement - Observe testing conditions indicated in opposite (locking torque to pressure ratio) column - Switch on System Tester. Select “Check transv. Testing concl. I important information lock” - Transmission cold / parking brake - Fully close transverse lock by applying approx.
Page 230 Differential. Transaxle Svstem Procedure Execution / Notes When measuring the breakaway torque, measure at Refer to page D39-213 for a listing of the actual values (admissible locking several locations (angular positions) within one wheel revolution. values) vs. the corresponding pressures. After the actual locking torque has been reached, Possible causes for deviation...
Page 231 Differential. Transaxle Svstem Procedure Execution I Notes Example: Measurement 2 = Gauge pressure lo...20 bar Actual values: Gauge pressure = 13 bar, locking torque measured = 240 Nm (177 ftlb) Specified value according to table at 13 bar: 120...300 Nm (88...221 ftlb) Measurement 2 o.k.
Page 232 Differential. Transaxle Svstem Execution I Notes 4. With the System Taster switched off - Open measuring line and transverse lock cylinder (to ensure that only pilot pressure is carefully (observing pilot pressure). Remove measuring line and fit bleeder valve. present at the measuring line), remove pressure gauge complete - Bleed transverse lock using System Tester 9288, with connecting...
Page 233 Differential. Transaxle Svstem Locking torque-to-pressure limits Locking torque (Nm) (ftlb) Pressure (bar) D39 - 213 PSD-Diagnosis / Troubleshooting Printed in Germany . XXVII, 1991...
Page 234 Differential, Transaxle System Checking pilot pressure valve of lock hydraulics (lock operation) General Normally the pilot pressure valve is checked within the scope of measuring the friction coefficient the transverse lock (test item 3). A pilot pressure valve (arrow) is located ahead of the transverse lock slave cylinder on the left-hand transmission side.
Page 235 Differential, Transaxle System Checking pilot pressure valves Procedure Execution 1 Notes 1. Prepare vehicle for pilot pressure - Connect ring flange (No. 3) to measuring line valve check. (No. 2). Proceed by fitting this assembly complete with banjo bolt, seals and fitting (Nos.
Page 236 Differential. Transaxle Svstem Procedure Execution 1 Notes - Connect System Tester 9288 along with adapter line 9288/l to diagnosis socket (located next to the passenger’s seat under the booster cover). Bleed pressure gauge by clocking lock solenoid valve complete with System Tester in “Drive links / Bleed position”...
Page 237 Differential, Transaxle System Lateral acceleration sensor Installation Installation position The sensor is fastened onto a welded-in sup- The lateral acceleration sensor has been port (2 bolts). The correct installation position installed on a support welded in under the LH (sensor in horizontal position) will be obtained seat.
Page 238 Differential, Tansaxle System The 55-pin ABS 2 LED adapter lead (see item I), a multimeter, a shop trolley jack and a measuring tape are required for this test. The 55-pin adapter lead required to run an ABS test on the Carrera 4 (964) and the 928 with %-pin PSD (instead of the adapter lead) has...
Page 239 Differential, Transaxle System 3. Establish a ground clearance of approx. 150 mm at the left front wheel by liffing the vehicle at the left front jacking point. Read off and record sensor voltage value. 4. Lower left front side of vehicle. Then raise vehicle at the front right end in the same manner by approx 150 mm.
Page 240 Differential, Transaxle System Assessment table for sensor tests Test item I Requirements Notes Fault I Troubleshooting Sensor installation position - Specified reading: volts when on a level surface via output voltage 2.7 f 0.14 the vehicle is switched on). (ignition The sensor is supplied If the reading exceeds or falls below the specification, this...
Page 241 Differential. transaxle svstem system tester 9288 PSD - Diagnosis with General information The PSD/ABS control unit is suitable for self- diagnosis. This means that the control unit can detect, store and output certain faults of the PSD and the ABS. Diagnosis is performed with system tester 9288 in combination with the adapter lead...
Page 242 trsnsaxle system Differential, Connector pin assignment for control unit (PSDIABS) 1 - Voltage, terminal 15 IO - Speed sensor output at rear light for (tire pressure monitoring system) control 2 - Operation of ABS rear-axle solenoid unit valve 11 - Vottage, terminal 30 3 - Ground, ABS solenoid valve, front tight 12*- Speed sensor output at rear lefl for 4 - K wire from diagnosis...
Page 243 Differential, transaxle system 37 - Ground, ABS solenoid valves, front let? + 17 - Monitoring, vottage supply for ABS so- lenoid valves rear axle 36 - Free 18 - Free 19 - Operation of ABS solenoid valva, front left 39 - Free 20 - Vottage for valve and motor relays on hy- 40 - Indicator lamp (green) for PSD function draulic unit...
Page 244 Differential, transaxle system memory Overview of the possible faull displays E,., 5%: Speed sensor, rear right sssssssssssssssssssssss El,, /-.- §§a Speed sensor, rear left Latsral acceleration 55: ABS valve, front left sensor, signal implausible sssssssssssssssssssssss sSssssssssssssSssssssss As.9 valve, Transverse lock, front right deviation...
Page 245 Differential, transaxle system Fault overview/Troubleshooting (diagnosis/test plan) Test point Fault display (short fault text) Page Transverse lock valve D39 - 230 Lateral acceleration sensor, D39 - 232 short circuit/discontinuity D39 - 233 Lateral acceleration sensor, signal implausible Transverse lock, deviation D39 - 234 Control unit defective D39 - 235...
Page 246 transaxle system Differential, DTC memory / Troubleshooting Important notes Combined plug connections - distinguish- ing between wires If warning displays light up and/or faults are shown in the DTC memory of the PSD/ABS, In the brake pad wear, speed sensor and HF they may also have been triggered by the fol- sending unit wiring there are several com- lowing problems:...
Page 247 Differential, transaxle system Replacing the hydraulic unit After installing/bleeding the ABS hydraulic unit, carry out a complete ABS test with the 2-LED tester. Test-drive after eliminating the fault. Clear the DTC memory after eliminating fault. Perform a test drive and then read out the DTC memory again.
Page 248 Differential, transaxle system Fault, DTC Possible causes, remedy, notes Test point Transverse lock valve No feedback signal from valve to control unit. DTC tl 1. Switch off the ignition. Pull the plug off the control unit. Check that circuits at plug are not interrupted. PIN 21 to PIN 23 PIN 21 to PIN 17 If necessary, interrupt the wiring path (plug on transverse...
Page 249 Differential, transaxle system Fault, DTC Possible causes, remedy, notes “i~:.~easra~~o~~amo~~e~~~f,t~o~~~o~s~~ob~-~e~ For this purpose, disconnect the plug connection on the trans- verse lock solenoid valve (armw). The transverse lock solenoid valve is located beneath the rear lefl wheel housing cover. Nominal value X.4 R between the PINS on the valve block.
Page 250 Differential, transaxle system Fautt, DTC Possible causes, remedy, notes Test point 2 Wiring between control unit and lateral acceleration sensor not in Lateral acceleration working order (discontinuky. short circuit to plus or short circutt to sensor, short-circuit/ ground), or the lateral acceleration sensor itself is damaged.
Page 251 Differential, transaxle system causes, remedy, notes Fault, DTC Possible Test point Lateral acceleration Signals from lateral acceleration sensor to control unit are incorrect. The sensor has a mechanical defect or its installation position is in- sensor, signal implausible correct. DTC 13 I.
Page 252 Differential, transaxle system Fault, DTC Possible causes, remedy, notes Test point Transverse lock, During the transverse lock regulating phase, the monitoring circuit in the PSD/ABS control unit has identified excessive variations be- deviation tween nominal actual values. DTC 14 Possible faults - Lock control circuit poorly bled (lock operation hydraulics) - Lock hydraulics leaking...
Page 253 Differential, transaxle system Fault, DTC Possible causes, remedy, notes Test point Control unit defedive Before replacing the control unit, check whether: - there is any electrical interference from the ignition voltage (for ex- DTC 15 ample, if the spark plug caps are not correctly attached) - them are any differences in potential caused by contact resistance (missing or poor ground connections).
Page 254 Differential, transaxle system Fault, DTC Possible causes, remedy, notes Test point Fmnt lefl No signal from speed sensor reaches control unit, or signal is incorrect I unrealistic. wheel sensor DTC 21 Important: This fault is also indicated if the PDAWABS control unit for the 911 Carrera 4 (964) is installed.
Page 255 Differential, transaxle system Fault, DTC Possible causes, remedy, notes 2. Checking the speed sensor signal. thts check, use the ABS 2-LED tester or an oscilloscope. Connect the ABS 2-LED tester to the control unit plug with the 55-pole adapter lead. If an oscilloscope is used, separate the speed sensor plug connection at the wheel suspension...
Page 256 Differential, transaxle system Fault, DTC Possible causes, remedy, notes Test point Front right General procedure as for DTC 21 (test point 6) 1. Internal resistance / continuity between PIN 47 and PIN 46 at control speed sensor unit plug. DTC 22 2.
Page 257 Differential, transaxle system Fault, DTC Possible causes, remedy, notes 1. Switch off the ignition and pull the plug off the control unit. Check PIN 19 of plug to PIN 17 and to PIN 23 for continuity. If necessary, interrupt the circuit (plug at hydraulic unit) and localize the discontinuity by reference to the wiring diagram.
Page 258 Differential, transaxle system Fault, DTC Possible causes, remedy, notes 4. Check whether the valve relay is energized (voltage is present at the solenoid valves). To make this check, connect all plugs and the relay. Push back the protective tube on the transverse lock valve plug (in the wheel hous- ing at the rear leff).
Page 259 Differential, transaxle system Fault, DTC Possible causes, remedy, notes Test point 13 Valve relay Certain faults in the ABS valve area (short circuit to plus or short circuit valve relay faults to ground in a control wire) may also be shown as DTC 34 the 9286 system tester.
Page 260 Differential, transaxle system Possible causes, remedy, notes Fault, DTC 2. Measure resistance between the following PINS at the control unit plug: PIN 19 to PIN 17 PIN 22 to PIN 17 2 to PIN 17 Nominal value approx. I...2 n PIN 21 to PIN 23 Nominal value approx.
Page 261 Differential, transaxle system Possible causes, remedy, notes Fault, DTC Re transverse lock valve + wiring: Separate plug connection at the transverse lock valve (arrow). Measure internal resistance of the solenoid valve. Nominal value 2...4 n If an incorrect value is obtained: Reolace transverse lock valve 3.
Page 262 Differential, transaxle system Fault, DTC Possible causes, remedy, notes from terminal the relay base Check wires Ll on 24 on the control unit plug and from L2 to PIN 35 for discontinuity. Important: The test from L2 to Pin 35 can be performed only if the warning contact of the pressure warning switch is closed (see wiring diagram).
Page 263 Differential. transaxle svstem Fault, DTC Possible causes, remedy, notes Test point 14 Return pump, 1. Switch off the ignition. Pull off the plug at the control unit. Check control circuk (wire with relay) - PIN 20 to PIN 5 - for discontinuity DTC 35 and short circuit to groundtto plus.
Page 264 Differential, transaxle system Possible causes, remedy, notes Fault, DTC 4. Check connections at ground wire (1) and plus wire (2) (contact re- sistance). Bridge terminals 30 and 87 at the relay base and check whether volt- age is present at the connection point (3).
Page 265 Differential, transaxle system Check lock hydraulics (energy production) General information The hydraulics comprises the high-pressure pump, solenoid valve, pressure reservoir and supply tank. The components are located on on a joint bracket in the rear-left wheel housing. The brake fluid for operating the transverse lock is obtained from the piston reservoir mounted on the high pressure pump.
Page 266 Differential. transaxle svstem Check hydraulics of the lock Troubleshooting This comprises: check of the lock hydrau- If the system is depressurized, the follo- lics without pressure gauge (special tool wing faults are possible: 9509). - Brake fluid reservoir (No. 12) empty (system leaks).
Page 267 Differential, transaxle system Important note If the pressure warning switch (No. 2) and / or the pressure reservoir (No. 5) is detached with the (No. removed, do not set down the pump upside down high-pressure pump (with the pressure If this is not observed reservoir connection facing down).
Page 268 Differential, Transaxle System Checking locking torque (friction coefficient) of transverse lock Tools 345/l-D3W5 Explanation Designation Special tool Order number 9509 Pressure gauge 000.721.950.90 9509/i High-pressure measuring 000.721.950.91 line 999.215.027.02 Ring flange 930.110.547.00 shorten threads by Banjo bolt approx. 4mm Seal N 013 811 2 2 pc.
Page 269 Differential, transaxle system Pressure tests on the lock hydraulics (energy production) Overview 1. Genera 2. Pressure gauge connection 3. Tests 4. Nominal values/Notes 1. General The following points can be checked by means of the pressure test on the differential - Connect pressure gauge 9509 - in combina- lock hydraulics (lock control):...
Page 270 Differential. transaxle svstem 3. Tests - Bleed pressure gauge (No. 1). To do this, connect a collection bottle to the pressure Note gauge bleeder valve (No. la) and open the valve. Operation of the pump is regulated by means Turn ignition key to position 2 (necessary of the ignition key for testing purposes.
Page 271 Differential, transaxle system a. Gas filling pressure of the pressure reser- c. Checking the switching points of the voir. pressure pump Cut-out pressure: Turn the ignition key to position 0 at approx. Turn the ignition key to po- 100 bar. Briefly open the bleeder valve on the sition 2.
Page 272 Differential, transaxle system 4. Nominal values/Notes Nominal values Notes Pressure reservoir - Gas filling pressure Replace pressure reservoir if the gas filling pres, 80 + 5 bar sure has reached or fallen below the wear limit wear limit 40 bar Switching points of the pressure warning If the actual values deviate from the nominal val- switch...
Page 273 Differential, transaxle system Notes Nominal values valve - Lock solenoid - Pump assembly First check the lock solenoid valve. Then remove the pressure line from the pump assembly (with the system depressurized). Connect high-pressure measuring line 950911 (No. 2) -without ring connector - to the pump assembly.
Page 274 Differential. transaxle svstem Removing and installing pressure Installing warning switch of lock hydraulics 1. Screw in the pressure warning switch (No. 2) and tighten to a torque of 26 Nm (19 fl- lb). Replace the O-ring if necessary. Pre- ‘I. Wtih the ignition key in position 0, pull off vent the pump assembly from turning while both plugs at the pump assembly.
Page 275 Differential, transaxle svstem 3. Attach plug to pressure warning switch 5. If necessary, connect pressure gauge - (plug on the pomp side remains discon- special tool 9509 -to the pressure reservoir nected at this point). and check the switching points of the pres- sure warning switch and also for leakage in the differential lock hydraulics.
Page 276 Differential, transaxle system and installing the press- Removing ure reservoir Removal 1. Pull off plug on the pump motor with the ignition key in position 0. 2. Completely depressurize the system. For this purpose, slowly open the bleeder valve on the lock solenoid valve and drain the brake fluid into a collection bottle.
Page 277 Differential. transaxle system 2. Bleed the pressure reservoir and lock so- 3. Repeat the last process (fully charging lenoid valve as follows: the pressure reservoir and then reducing Open the bleeder valve on the lock solenoid the reservoir pressure to zero) approx. f-2 times (brake fluid must be free from valve.

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