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Porsche 930 TURBO - 1989 GENERAL DATA Manual

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General
Data
TRANSMISSION
TYPE
930
The following transmissions are installed in the 930 Turbo:
930/30 -4-speed with rear axle final drive 9/38 (standard)
930/32 -4-speed with rear axle final drive 9/36 (not for USA)
The following transmission is installed from 1977 Models:
930/33 -4-speed with a final drive ratio of 9/38
From 1978 Models with the following transmission:
930/34
-4 gears with final drive ratio of9/38

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Summary of Contents for Porsche 930 TURBO - 1989 GENERAL DATA

  • Page 1 General Data TRANSMISSION TYPE The following transmissions are installed in the 930 Turbo: 930/30 -4-speed with rear axle final drive 9/38 (standard) 930/32 -4-speed with rear axle final drive 9/36 (not for USA) The following transmission is installed from 1977 Models: 930/33 -4-speed with a final drive ratio of 9/38 From 1978 Models with the following transmission: 930/34...

  • Page 2: General Data

    General data 911 turbo Five-speed transmission G50/50 88-227 A new five-speed transmission has been installed in the 911 Turbo worldwide from Model 89 onward. This gearbox corresponds to the G 50/00 Carrera gearbox with regards to construction and repair. The gearbox has been reinforced, however, and the transmission ratios modified to suit the high engine performance of the turbo engine.
  • Page 3 General Data MANUAL TRANSMISSION TORQUE SPECIFICATIONS Location Threads Designation Material Torque NM (kpm) Drive shaft M 30xl.5 210 -230 (21.0 -23.0) Drive shaft M 20xl.5 C 35 V 160-180 (16-18) Driven shaft M 24xl.5 190-100 (19-20) (2. 6 -3. 0) Stub axle M IOxl.5 Stretch bolt...
  • Page 4 Location Threads Designation Material Torque Nm (kpm) Guide tube M 6xl.O Capscrew 8-10 (0.8-1.0) Clutch and M 8xl.O 20-'-5 Capscrew starter gear (2.0-2.5) Starter Hex nut M lOxl.5 46-50 (4.6-5.0) Mech. controls Holder to base Hex hd screw (0.6) Base to tunnel Socket head (2.1) capscrew...
  • Page 5 General General Data Manual Transm. 930/30, 930/32. 930/33 and 930/34 Ratio 16/36 i = 2.25 1st gear 23/30 i = 1.3043 2nd gear 28/25 i = 0.8929 3rd gear 32/21 i = 0.6563 (32/20 i = 0.625) 4th gear 16/39 i = 2.4375 Reverse Climbing in 0;0...
  • Page 6 General Data Technical Data Printed in Germany -III. 1978 30-07...
  • Page 7 Removing and Installing Clutch Disc Printed in Germany -III, 1978 30 -1...
  • Page 8 Clutch, Control Removing and Installing Clutch Disc Printed in Germany...
  • Page 9 Clutch, Control Notes when Qty. Remarks Description Removing Installing Clutch bolts Tighten evenly and Unscrew evenly torque: 2.0-2.5 mkg (14 -18. 5 ft Ibs) diagonally Clutch bolts Unscrew evenly Tighten evenly and torque: 2,0-2, 5 mkg DIN 931 from (14 -18, 5 ft Ibs) diagonally.

  • Page 10: Removing And Installing

    Clutch, Control REMOVING INSTALLING Note Removing 1. Hold flywheel with toothed segment P 201 a Clutch linings cannot be replaced. and spacer sleeve. Make sure that spacer sleeve If applicable, the entire disc is to be replaced. fits engine with adequate clearance. 5.
  • Page 11 Clutch, Control CHECKING CLUTCH PRESSURE PLATE/DISC The MFZ clutch pressure plate from Fichtel and Sachs is not designed for reconditioning or repairing. The inspection is limited to dry cleaning and removing dust with compressed air and emery cloth, and a thorough visual! examination. 1.

  • Page 12: Clutch, Control

    Clutch, Control Installing 1. After cleaning. check clutch contact surface of flywheel for wear. If necessary, machine surface and smooth with emery cloth. Replace the flywheel, if necessary. 2. Lubricate needle bearing in flywheel with about 1 cm3 (1,5 grams) of MoS2 grease. 3.
  • Page 13 Clutch. Controls ADJUSTING CLUTCH FROM 1977 MODELS (with clutch servo on transmission) Note Because of the clutch servo it is no longer possible to check the clutch play exactly at the clutch pedal. This is why the clutch play of cars with a servo clutch has to be checked at the transmission adjusting lever.
  • Page 14 DISASSEMBLING ASSEMBLING CLUTCH III, 1978 - Disassembling and Assembling Clutch Printed in Germany 30 -8...
  • Page 15 Note When Special Qty. Description Instructions Removing Installing Bolt Washer If necessary. replace Pressure plate Drive plate Check for wear. center with a mandrel Starter gear ring Release bearing Check. replace if Only possible, Don't subject when pressure necessary. Do not pressure -danger plate not loaded...
  • Page 16 REMOVING AND INSTAlliNG CLUTCH RELEASE SPRING (FROM 1978 MODELS) Removing Checking Lubricating 1. Loosen clutch cable at holder and detach 1. Check movement of release lever on at release lever. release lever shaft, correcting if not easy enough. 2. Remove adjusting lever, by taking off the circlip and, if applicable, disconnecting 2.
  • Page 17 Clutch, Controls 2. Press back release lever with a suitable tool until release spring passes the top dead center point (lever snaps against stop on console) . 3. Remove adjusting lever again and mount as close as possible to release lever. 4.
  • Page 18 Clutch ADJUSTING CLUTCH ON CARS WITH POWER CLUTCH (FROM 1978 MODELS) Checking Clutch Play Basic Adjustment Because of the power assistance it is no longer 1. Detach clutch cable or loosen completely at possible to exactly determine clutch play by holder.
  • Page 19 Note 5. Measure release travel. Clutch cable tightness is correct, if when engaged the release lever just lifts off of stop. a) Apply calipers with clutch engaged (see figure) and read distance I (e.g. 101.9 mm). b) Disengage clutch and measure distance II as shown in figure (e.g.
  • Page 20 911 turbo Clutch, Control Clutch mechanism, disassembling and assembling, from Model 89 onward C!f~ 155/30 30 -15...
  • Page 21 Clutch, Control 911 turbo Note when: Oty. Description Removing I Installing Hexagon head screws M 6 x 16 Bracket Install in correct position Bearing cover Pack with grease, use Olista Longtime 3 EP Needle bearing with as- Install in correct posi- sembly hole tion, assembly hole points outwards...
  • Page 22 gear -shift system -actuat.. hous. 34-1 Dismantling and Assembling Front Transmission Cover Printed in Germ~ny Mech.
  • Page 23 Mech. gear -shift system -actuat.. hous. Notes Amt. Designation Remarks Installing Removing Drive onto stop Sea] Pry out with screwdriver . with appropriate mandrel Drive out. Reverse shaft Heat cover to ca. 120 C and drive in Drive out Heat co~er to Operating lever spacer ca.
  • Page 24 Mech. gear -shift system -actuat.. house TOOLS Remarks Special Tool Designation Mandrel Part of P 254 P 254 b Pressure pad Pressure pad P 254 c Dismantling and Assembling Gear Housing 34-3 Printed in Germany...
  • Page 25 Manual Transmission/Controls Case Printed in Germany 34-4 Dismantling and Assembling Gear Housing...
  • Page 26 gear -shift system -actuat.. hous. Notes Amt. Designation Remarks Removing Installing Cotter pin Replace Washer Operating lever Operating lever Coat with shaft univexsal lubricant Washer Torque to Plug specifications Cotter pin Replace Reverse operating lever ReveIse rod Removing with Install Snap ring small screw- correctly.
  • Page 27 Mech. gear -shift system -actuat.. hous. DISMANTLING AND ASSEMBLING INSTRUCTIONS Dismantling Note 1. Remove snap rings for bearing outer races The bearing outer races have different with P 254 b or 254 c. inside diameters. The bearing outer race with the largest inside diameter belongs to the driven shaft cylindrical roller bearing.
  • Page 28 Mech. gear -shift system -actuat.. hoDs. TOOLS Special Tool Remarks Designation Pressure pad P 254 d Local Manufac. Hook Mandrel P 375 Pressure pad P 254 a P 265 c Pressure pad 34-7 Dismantling and Assembling Transmission Case Printed in Germany...
  • Page 29 gear -shift system -actuat.. house Printed in Germany 34-8 Dismantling and Assembling Transmission Case Mech.
  • Page 30 Notes Designation Remarks Installing Removing Capscrew Torque to specifications Lockwasher Replace. if necessary Guide tube Lubricate with MoS2 paste Tube, drive Pullout shaft seal with hook Light coat of oil for seal and lip Circlip Release lever Adjust Seal Lever shaft Coat with a MaS lubricant Release fork...
  • Page 31 Mech. gear -shift system -actuate hous Notes Designation Amt.1 Remarks Removing Installing Electronic speedo- meter sensor Spiral pin Hex hd screw Torque to specifications Spring Lock Drill out Plug Spiral pin Lock Plug with Torque to magnet specifications Shaft seal Drive in with P 265 c Outer race...
  • Page 32 Mech. gear -shift system -actuat.. hous DISMANTLING ASSEMBLING INSTRUCTIONS 4. Drive out bearing out race of drive pinion Dismantling bearing with P 254 d. 1. Pullout guide tube for drive shaft seal with local manufactured hook. 2. Drive out spiral pin for release fork. Assembling 1.
  • Page 33 gear -shift system -actuat.. hous. 3. Screw in vent correctly (bore in hexagon must 5. Drive in lever shaft bushings with P 375. face forward toward transmission cover). 4. Install selector rod locks. 1 -Bearing sleeve (Delrin) 2 -Lever shaft bushing (short) 3 -Transmission Case 4 -Guard 5 -Lever...
  • Page 34 6. Adjust release forks and release levers. The 7. Drive in stub axle seal with P 265 c. distances are 76.5 mm and 93 mm. Note Insert the drive shaft seal guide tube after installation of the drive shaft.
  • Page 35 Manual Transmission. Controls Case TRANSMISSIOf,! CASE WITH CLUTCH BOOSTER ":i 12 11 ". II. 1976 - " , Printed in Germany Disassembling and Assembling Transmission Case 34 -14...
  • Page 36 Manual Transmiss ion, Controls, Cas e Notes Qty. Description Remarks Removing Installing Replace, if necessary Circlip Adjusting lever Adjust Seal Replace. if necessary Dowel pin Coat spring pin with Release lever a multi-purpose grease containing MoS2 Seal Replace. if necessary Replace.
  • Page 37 Manual Transmission. Controls, Case Notes Qty. Description Remarks Installing Removing Drive out with Drive in with P 375 Bushing until positioned correct- P 375 Protective pipe Drive out with Drive in with P 375 Bushing P 375 until positioned correctly Replace, drive in with Bushing fitting mandrel...
  • Page 38 Manual Transmission. Controls. Case DISASSEMBLING ASSEMBLING INSTRUCTIONS Note Disassembling 1. Take tension off of spring to remove the Only mount the adjusting lever after the engine/ release lever. This is done by pressing the transmission assembly has been installed in car. release lever toward the front transmission cover with an appropriate tool.
  • Page 39 Manual Transmission, Controls, Case T~ANSMISSION CASE WITH POWER CLUTCH FROM 1978 MODELS Disassembling and Assembling Transmission Case 34 -14 Printed in Germany -III, 1978...
  • Page 40 Manual Transmission, Controls, Case Note When Special Qty. Description Removing Instructions Installing Circlip Adjusting lever Hex head bolt Spring washer Spring mount Spring Seal Replace Release lever Hexagon nut Spring washer Base Lever shaft a-ring Replace Release fork Seal Replace Seal Replace Drive out with...

  • Page 41: Transmission Case

    DISASS EMBLING AN D ASS EMBLING TRANS MISSION CAS E Disassembling 2. Install release lever with spring (see page 30 -11). 1. Remove release lever with spring (see page 30 -11). 2. Drive out bearing bushings with 9167 and man- drel from P 254.
  • Page 42 TOOLS Special Tool Remarks Designations Installing lever Local manufacture Pressure pad P 299 Printed in Germany Dismantling and Assembling Gearshift Base 34-15...
  • Page 43 Manual Transmission/Controls, Case 34-16 Printed in Germany Dismantling and Assembling Gearshift Base...
  • Page 44 Mech. gear -shift system -actuat., house Notes Amt. Remarks Designation Installing Removing Gearshift knob Check for damage and tightness Tolerance ring Replace Seal Capscrew M 8 x 20 Torque to (socket hd) specifications Washer Replace. if necessary Capscrew M 6 x 20 Torque to (socket hd) specifications...

  • Page 45: Disman Tlin G An D Ass Embling

    Mech. gear -shift system -actuat.. hous Notes Amt. Remarks I N°-I Designation Installing Removing Replace, if Lock necessary Washer Fork Coat bearing surfaces with MaS lubricant DISMAN TLIN G AN D ASS EMBLING INSTRUCTIONS Assembling Dismantling 1. Clamp geanhift base in a vise. Move 1.

  • Page 46: Gearshift Mechanism

    gear -shift system -actuat.. hous. ADJUSTING GEARSHIFT MECHANISM Loosen selector rod clamp. Turn selector rod for transmission's inner selector lever left in idle to stop (as seen in driving direction). 2. Move selector lever in idle position so that the lower part of the selector lever is vertical and on rigth stop (3rd and 4th gear).
  • Page 47 TOOLS Special Tool Remarks Description No. 9106 Holder Disassembling and Assembling Gears/Shafts Printed in Germany 1976...
  • Page 48 Manual Transmission. Gears/Shafts Disassembling and Assembling Gears/Shafts Printed in Germany...
  • Page 49 Mech. gear -shift system -gears, shafts Notes Designation Remarks Installing Removing Hex nut Torque to specifications Washer Washer One in front and one behind ground strap Ground strap Holder Holder Front transm. cover Reverse gear II Gasket Replace Replace. Torque to Block trans- mission with specifications...
  • Page 50 Mech. gear -shift system -gears, shafts Notes Amt. Designation Remarks Installing Removing Torque to Backup light switch specifications Install correctly. Long end faces in Hex nut Torque to. specifications Washer Gear housing Move selector rods to off position and remove Gasket Replace Transmission case...
  • Page 51 Mech .gear -shift system -gears, shafts REMOVING INSTALLING INSTRUCTIONS Removing Pull off cylindrical rollex bearing toward front. 1. Loosen nuts for drive pinion and drive shaft. Place reverse gear shaft or other corresponding shaft in bore of gear housing. Slide on reverse gear II as illustrated and place in 4th.
  • Page 52 Installing 5. Install nut for drive pinion with a fluid adhesive (Loctite No. 73) and torque to 1. Install shims in number and thickness as specifications. Treat threads with Locquic noted or as determined while adjusting the Activator to assure a perfect lock. pinion.
  • Page 53 Manual Transmission / Gears, Shafts ADJUSTING INSTRUC"TIONS Note 6. Install operating lever for reverse gear. Torque drive pinion and drive shaft nuts to Reinstall reverse gear II. specifications to adjust selector forks. 1. Install reverse gear selector rod. 2. Install Special Tool 9106 and assemble reverse gears I and III.
  • Page 54 Manual Transmission, Gears/Shafts 9. Adjust gearshift sleeves so that they are at dead center between the synchronizing rings in idle position. 10. Torque hex head screws of selector forks to specifications. Note Correct deviations in adjustments after completion of shifting controls, because they are essential for proper functioning of the synchronization.
  • Page 55 Mech. gear -shift system -gears, shafts TOOLS Special Tool Remarks Designation No. 9104 Holder No. 9105 Socket wrench 35-9 Printed in Germany Dismantling and Assembling Drive Shaft...
  • Page 56 Mech. gear -shift system -gears, shafts 35-10 Dismantling and Assembling Drive Shaft Printed in Germany...
  • Page 57 Notes Designation Remarks Installing Removing Torque to specifications and lock. Rev. gear Collar faces out. Pry off with 2 screwdrivers. Cyl. rollex Remove with Heat to ca. 120 C and drive on. extractor bearing 1st gear I Remove with Replace in pairs only.
  • Page 58 Mech. gear -shift system -gears, shafts Notes Amt. Designation Remarks Installing Removing Remove with Heat to ca. Cylindrical roller bearing spare sleeve 120 C and drive on. Inner race Remove with Heat to ca. spare sleeve 120 C and drive on. 4-point bearing Inner race...
  • Page 59 DISASSEMBLING AND ASSEMBLING INSTRUCTIONS Disassembling 2. Press off 4th speed bushing. 4-point bearing and cylindrical roller bearing with a spare operating sleeve. Note For better understanding the blow-up drawing shows the entire drive shaft without a clamping plate. The parts up to and including number 16 are dismantled and assembled without removing the drive shaft (refer to "Removing and Installing Change Gear").
  • Page 60 Manual Transmission. Gears/Shafts TOOLS Special Tool Description Remarks Guide sleeve No. 9108 35-15 Disassembling and Assembling Drive Pinion Printed in Germany -I. 1976...
  • Page 61 Manual Transmission. Gears/Shafts Disassembling and Assembling Drive Pinion 35-16 Printed in Germany...
  • Page 62 Mech gear -shift system -gears, shafts Notes Description Remarks Installing Cyl. roller bearing Remove with Heat to about 1200 C extractor and drive on Thrust washer Plane ground side faces needle bearing 1st speed gear II Check synchro, replace 1977 Models -with in pairs only assyrnrnetrically profiled teeth on...
  • Page 63 Mech. gear -shift system -gears, shafts DISA SSEMB LING A SSEMB LING IN STRUC TION Assembling Disassembling 1. Heat cylindrical roller bearing to about Note 120oC and drive on. The blow-up drawing shows the entire drive Note pinion without clamping plate for better understanding.
  • Page 64 TOOLS...
  • Page 65 Mech. gear -shift system -gears, shafts Notes Amt. Designation Remarks Installing Removing Seal Lubricate slightly. Seal Remove with Drive in to stop with pressure sleeve. screwdriver Pipe Printed in Germany Removing and Installing Drive Shaft Seal 35-20 INo.
  • Page 66 REMOVING AND INSTALLING INSTRUCTIONS 5. Pry off seal with screwdriver. Do not use Removing tube as leverage. Use a piece of wood for 1. Remove engine/transmission assembly and this purpose. unbolt transmission. 2. Unscrew guide sleeve capscrews and remove guide sleeve. Installing 1.
  • Page 67 2. Install rubber seal. 3. Lubricate rubber seal and sealing lip. 4. Insert tube with rubber seal and seal 5. Install guide sleeve for release bearing and coat with MoS paste. 6. Bolt transmission to engine and install this assembly. 35-22 Printed in Germany Removing and Installing Drive Shaft Seal...
  • Page 68 Notes Amt. Remarks Designation Installing Removing Remove with Install correctly. Snap ring small screw- must fit properly. driver Lockwasher Check for wear, Synchronizer ring install correctly. Stop Install correctly Lock Install. correctly stop Gear 35-23 Dismantling and Assembling Synchronization Printed in Germany...
  • Page 69 Mech. gear -shift system -gears. shafts Notes Amt. Remar ks Designation Installing Removing Remove with Install correctly. Snap ring small screw- must fit properly driver Lockwasher Check for wear, Synchronizing ring install correctly Install correctly Stop Install correctly Lock Install correctly Stop 1st speed gear 35-24...
  • Page 70 DISASSEMBLING ASSEMBLING INSTRUCTIONS Disassembling 2. Insert lockwasher and install snap ring so that the opening is well located in the area of 1. Lift out snap ring with a small screwdriver the guide groove. and remove lockwasher. MODIFICATIONS -1977 MODELS Assembling Synchronization for 1st and 2nd gears has been changed.
  • Page 71 Mech. gear -shift system -gears, shafts Check the following points to assure perfect synchronization. 1. Check diameter of installed synchronizing ring with a micrometer. Apply the micro- meter at the highest position of the synchronizing ring. Diameter: 1st and 2nd gear = 86.4 -0.25 3rd and 4th gear = 76.3 -0.17 2.
  • Page 72 Differential, Final Drive TOOL Special Tool Remarks Designation Pressure pad P 265 c 39-1 Removing and Installing Differential Printed in Germany...
  • Page 73 Differential, Final Drive Printed in Germany Removing and Installing Differential 39-2...
  • Page 74 Differential, Final Drive Notes Amt. Designation Remarks Installing Removing Stretch bolt Torque to specifications Washer Flange Hex nut Torque to specifications Replace if Washer necessary Side cover Drive off with plastic hammer Seal Replace, lubricate slightly Shaft seal Drive out punch Drive in with P 265 c Heat cover to ca.
  • Page 75 Differential. Final Drive REMOVING INSTALLING INSTRUCTIONS Removing 1. Loosen flange stretch bolt and remove flange. Installing 1. Heat transmission cover to about 120 C and drive in bearing outer race. 2. Drive in flange seal with P 265 c, 39-4 Removing and Installing Differential Printed in Germany...
  • Page 76 TOOLS Special Tool Remarks Designation Pressure pad P 264 b Pressure pad P 263 Extracter Kukko No. 20/1 Dismantling and Assembling Differential 39-5 Printed in Germany...
  • Page 77 Differential, Final Drive Printed in Germany 39-6 Dismantling and Assembling Differential...
  • Page 78 Differential. Final Drive Notes Amt. Remarks Designation Installing Removing Replace, if Spiral pin necessary Differential pin Spiral pin bore aligns with bore in anchor Anchor Differential gear, Turn and Coat semiround small remove surface with MoS paste Coat semiround Large differential gear with threaded surface with MoS2 disc...
  • Page 79 Differential, Final Drive DISMANTLING ASSEMBLING INSTRUCTIONS Dismantling 3. Insert large differential gears with press fit threaded discs through oval opening 1. Remove taper roller bearing with an in differential housing and align with extracter and P 263. flanges. Note 4. Place small differential gears between the large differential gears and turn until the The claws of both arms must be machined.
  • Page 80 Disassembling and Assembling Differential Printed in Germany -IlL 1978 39 -8a TOOLS...
  • Page 81 Differential, Final Drive 12 11 14 2 "/' ..,/ /"" /" IV. 1981 -Printed in Germany Disassembling and Assembling Differential 39-8b...
  • Page 82 Differential. Final Drive Note When Special Description Instructions Removing Installing Spiral pin Small differential Coat with MoS2 pinion paste. Only replace in sets (with large differential pinions) Large differential Coat with MoS pinion paste. Only rep1ace in sets (with small differential pinions) Threaded piece Knock on with P 264...
  • Page 83 Differential. Final Drive D ISASS EMBL ING ASS EMBLING DIFFERENTIAL 3. Knock ring gear off of housing. Disassembling 1. Knock out spiral pin for differential pins. Assembling 2. Pull off tapered roller bearing inner races with a puller (e.g. Kukko No. 20/1) and special tool P 263.
  • Page 84 2. Tighten ring gear bolts to specified torque. Slide lockplate into groove of bolts, squeeze front end with a pliers (to firmly unite lock- plate with bolts) and lock by bending lockplate down over side of bolt head. 3. Coat differential pinions with MoS2 paste. 4.
  • Page 85 Differential. Final Drive Recommended Order for Readjustment of Pinion/Ring Gear If it is necessary to adjust the drive pinion and ring gear. the following procedures are recommended for efficiency. " (5 plus 5 1. Determine total shim thickness "5 specified pre-load tapered roller...
  • Page 86 Differential, Final Drive ADJUSTING DRIVE PINION RING GEAR General Notes Drive pinion and ring gear se!tings are important for a long service life and quiet running of the final drive. This is why drive pinions and ring gears are matched during production and checked on special testing machines for the most favorable surface appearance and low noise levels in both directions of rotation.
  • Page 87 Differential, Fina Drive TOOLS Special T oo[ Remarks Description VW 385/1 9109 VW 385/54 R -81.69 Commercial item Commercial item 3 mm range VW 385/14 VW 385/56 30 mm long VW 385/17 Gauge plate VW 387 Clock gauge holder 9145 Sleevf! VW 521/4 Adjusting device...
  • Page 88 Differential. Final Drive ADJUSTING DRIVE PINION 1. Install preassembled drive pinion and Distance "E" is calculated by adding together design drive shaft without shims and torque distance "R" and deviation "roo as indicated on face of drive pinion. clamping plate nuts to specifications. R = 81.69 mm for transmission type 930/32 R = 82.29 mm for transmission type 930/30/33/34 2.
  • Page 89 8. Torque drive pinion nut to specifications. 13. Set master gauge VW 385/30 to pinion setting (82.41 mm in example) and place on master mandrel. Set dial gauge (3 mm range) at zero with 1 mm preload. 9. Make sure that the taper roller bearing outer races fit tight in transmission case and side.
  • Page 90 Differential. Final Drive 16. Place gauge mandrel in transmission case. 19. Turn master mandrel carefully until dial gauge The dial gauge extention is near the gauge extension is vertical to face of drive pinion head. plate. At this moment the dial gauge needle will reach its maximum point of deflection (inflection).
  • Page 91 Differential. Final Drive ADJUSTING RING GEAR Determining total shim thickness "S ..(5 + 5 ) tot 1 Ring gear must be readjusted after replacement of 5. Place gauge VW 385/17 on collar of differen- tial. transmission case, side transmission cover, tapered roller bearing for differential, differential housing or pinion/ring gear set.
  • Page 92 Differential. Final Drive 8. Calculate"S ". Thickness of spacer S .'S "= shi~tthickness + measured value + tapered roller bearing preload 6, 15 mm = 3, 075 mm 0, 20 3, 275 mm Example: Shim thickness 5, 00 mm Note Measured value O-.82mm Preload (constant vMttej...
  • Page 93 ADJUSTING BACKLASH Backlash should be 0, 14 to 0, 20 mm. 6. Turn differential in both directions several times to settle the tapered roller bearings. Install pinion/ring gear set with shims"S .. used for pinion setting. 7. Mount dial gauge holder VW 387 with dial Note gauge and plain extension that dial gauge axis and lever are at right angles.
  • Page 94 Differential, Final Drive 9. Repeat measurement three times. turning ring gear 900 each time. Measured values must not deviate among each other by more than O. 05 mm. Note Backlash required is inscribed in ring gear. 10. If specified backlash is not reached. change spacers (5 and 5 ) again.
  • Page 95 Differential, Final Drive TOOLS Printed in Germany 1976 Disassembling and Assembling Limited Slip Differential 39 -21...
  • Page 96 Differential, Final Drive Printed in Germany Disassembling and Assembling Limited Slip Differential 39 -22...
  • Page 97 Differential. Final Drive Note When Qty. Description Remarks Installing Removing Socket head screw Torque to 1,4 mkg (10 ft Ib) Housing cover Thrust washer Insert properly Outer splined disc (wavy) Outer splined disc Inner splined disc (molybdenum surface) Outer splined disc Pressure ring Gear Install properly...

  • Page 98: Slip Differential

    Differential. Final Drive DISASSEMBLING ASSEMBLING LIMITED SLIP DIFFERENTIAL (400/0 Locking Effect) b. Pressure Rings Disassembling The guide tabs and bearing surfaces must 1. Remove ring gear. not show excessive wear or scoring. They must also move easily in differential housing. 2.
  • Page 99 Differential, Final Drive Note Caution During the model year 1976, inner splined discs To prevent changing the locking effect, it is and outer splined discs will be modified. essential that the discs be reinstalled in their The present inner splined molybdenum coated proper positions.

This manual is also suitable for:

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