porsche 928 factory manual - volume 3

7/22/2019 Porsche 928 Factory Manual - Volume 3

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Workshop Manuall

DR. ING. h. c. F. PORSCHE Aktiengesellschaft


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The Workshop Manual is only for the internal use of the Porsche Dealer Organization.

@ 1977 Dr. Ing. h.c. F. Porsche AktiengesellschaftSales, D-7140 Ludwigsburg

All rights resewed - Printed in Germany XX, 1986

WKD 481 621Print No. W 42-608-126-l


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List of Repair GroupsGeneral Technical Data Paae 0.1RepairGroups

Maintenance, Self-diagnosisGroup

03Engine Engine, CrankcaseEngine, Crankshaft, PistonsEngine, Cylinder Head and Valve DriveEngine, LubricationEngine, CoolingFuel SupplyAir Flow Controlled Fuel injectionExhaust System/Emission ContrdsStarter, Power Supply, Cruise ControlIgnition System

10131517192024262728

Transmission

Chassis

Clutch, Controls 30Torque Converter 32Manual Transmission, Controls, Case 34Manual Transmission, Gears, Shafts 35Automatic Transmission, Controls, Case 37Automatic Transmission, Gears, Valve Body 38Differential, Transaxle System 39Front Wheel Suspension 40Rear Wheel Suspension, Axle Shaft 42Wheels, Tires, Alignment 44Antiblock System 45Brakes, Mechanical 46Brakes, Hydraulics 47Steering 48Body-Front Section 50Body-Center Section 51Body-Rear Section 53Lids 55Doors 57Hardtop 61Bumpers 63Glasses, Window Control 64Exterior Equipment 66Interior Equipment 68Seats 72Seat Covers 74

Heating, Heater 80Ventilation, Ventilation 85Air Condition Air Conditioner 87Electrics Instruments, Fuel Gauge, Alarm SystemRadioWindshield Wipers and WasherExterior Lights, Lamps, SwitchesInterior LightsWiring

909192949697

Printed in Germany - XX, 1997


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928 Table of contents Volume IIIa

General DataTechnical dataTightening torquesTorque ConverterRemoving and installing torque convener 32-101Removing and installing selector lever cover frame 37-101Removing and installing selector lever cable 37-103Adjusting selector lever cable 37-105Removing and installing starter locking and backup light switch 37-107Adjusting starter locking and backup light switch 37-109Checking adjustment of selector lever cable and starter locking / backup light switch 37-l 11Bowden cable for control pressure, removing and installing (service solution) 37-113Bowden cable for control pressure, adjusting 37-115Removing and installing transmission 37-l 17Adjusting transmission suspension 37-123Disassembling and assembling front convener housing 37-125Disassembling and assembling front converter housing (87 models onward) 37-l 30Removing and installing rear transmission case 37-131Removing and installing rear transmission 37.135Disassembling and assembling transmission 37-143

Transmission I Gears, Valve BodyChecking transmission operation ....................Checking operation ...........................Checking operation (87 models onward) ................Troubleshooting. ............................Removing and installing shift valve casing ...............Disassembling and assembling shift valve housing ..........Disassembling and assembling shift valve casing (87 models onward)Removing and installing lower cover ..................Disassembling and assembling lower cover ..............Replacing ATF and filter ........................Flushing ATF cooler and lines .....................Removing and installing governor ...................Checking governor ...........................Removing and installing vacuum modulator ..............Removing and installing primary pump. ................

38-10138-l 1038-11 Oa38-11138-12338-l 2538-130a38-13138-13338-13738-14138-14338-14538-14738-149

Page

30-010130-0105

-Table of contents 1Prlnwd in Germany XXXV, 999


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Volume III Table of contents 929

Disassembling and assembling secondaty pump ............... 38-l 55Disassembling and assembling gear assembly ................ 38-l 57Disassembling and assembling one-way clutch ................ 38-163Disassembling and assembling clutch K 1 .................. 36-l 69Disassembling and assembling clutch K 2 .................. 38-177Differential I Transaxle systemRemoving and installing final drive ................ ......Disassembling and assembling final drive ..................Disassembling and assembling differential ..................Disassembling and assembling bearing assembly ..............Disassembling and assembling bearing assembly / Determining thickness ofshims for bearing assembly ................ ..........Adjusting drive pinion and ring gear. .................. ...Adjusting drive pinion and ring gear. ................. ....Adjusting drive pinion and ring gear. ................. ....Adjusting drive pinion and ring gear. ................. ....Adjusting drive pinion and ring gear. ................. ....Adjusting drive pinion and ring gear. ................. ....Disassembling and assembling central tube .................Checking central tube .............................PSD-Diagnosis I Troubleshooting ................ .......

39-l 0139-10739-11339-l 1939-12339-12539-12739-12839-13039-13339-13539-13739-139D39-201

2l

Table of contentsPrinted In Genany - XXXV. 1999


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928 General Data 30a 4 - SPEED AUTOMATIC TRANSMISSION (UP TO '86 MODELS)

1 - Front converter casing 2 - Automatic transmissiona 3 - Final drive

Transmission TypeA 28.01A 28.02

A 28.03

A 28.04A 28.05

0 A 28.06

A 28.07A 28.08

A 28.09

A 28.11

installed in928 S, USA series / '83 and '84 models for Japan928 S, Special option for Europe / rest of theworld, '84 models928 S, Special option (M 251) Europe / rest

of the world 3/84 onward (as 28.02, butrear axle transmission ratio 13 : 33)928 S, USA series / '85 models for Japan928 S, Special option Europe / '85 modelsrest of the world928 S, Special option (M 251) Europe / '85 modelsrest of the world (as A 28.05, but withrear axle transmission ratio 13 : 33)928 S, USA series / '86 models for Japan928 S, Special option Europe / '86 modelsrest of the world928 S, Special option (M 251) Europe / '86 modelsrest of the world (as A 28/08, but withrear axle transmission ratio (13 : 33)928 S, Australia series, special option (M 299)for FGR, Switzerland, Austria, Sweden('86 models)

0 Printed in Germany-XX,1988 Technical Data 30 - 0101


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30Technical Data

General Data 920

0

4-speed automatic transmlsslon (87 models onward)

1 - Front converter casing3 - Final drive

2 - Automatic transmission

Type Key-number Equipment Installed In model aA28.12 - 928 S 4 USNJap. 87188A28.14 - 928 S 4 R.d.W. 87188A28.16 - 928 S 4 worldwide 89/90/91A28.18 - 928 GTS worldwide 92/93

30 - 0102 Technical DataPrinted in Germany - XXXI, 1993


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928 General Data 30a Technical Data

Tmsmlsslon DeslgnatTon1

A 28 02 12 1 6 E 05065T -r

[ - @zFc,985

1 = 5 - speed transmission6 = AutomaticTransmission for 8 cylinder vehiclesLimited-slip differential 40 %Country codeTransmission typeA 28 = four speed automaticA 22 = three-speed automaticG 28 = five-speed manual transmission

72227012 01 722316 02.~ A28.01 7222702501 72231602...= A28.07722 270 14 01 722 318 02...= A 28.02/03 7222702601 72231602.~ A28.117222701701 72231602...= A28.04 722 270 21 01 722 326 02...= A 28.12/14722 270 18 01 722 318 02...= A 28.0.5/06 7222703201 72236003...= A28.16722 270 21 01 722 318 02...= A 28.08/09 7222703401 72236003...= A28.18

Technlcal DataPrinted in Germany - XXXI, 1993

30 - 0102a


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30 General Data 928Technical DataTransmlssion numbers (12 dlglts)

A2814TIndex for varlantswlthln the assembly number0 = no differential1 = normal differential2 = ZF limited slip differential3 = proportional slip differential

Model year SerlalnumberJ = 1988 e.g. 00903K = 1989L = 1990M = 1991

Note:As from model 88. the gear box number will be readable from below, stamped on the rear stiffeningrib of the rear-axle housing* As of MY 92, the model letter is omitted.

30 - 0102b Technical Data aPrinted in Germany - XXXI. 19 93


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928 30

General data

Ratios1st gear2nd gear3rd gear4th gearRDckw&tsgangFinal driveFinal drive ratio

(Stall speed)

Capacity, rearaxle final drive

Oil grade

Capacity, auto.unl withconverter

A28.0 1/04/07/l 2 R8.02/03/05/06/08/09/11/14/16/18Fully automatic 4-speed sun-an&planet transmis

3682941I,441 oo5,14

Drive pinion without hypoid displacement

mA 28/t 63,872,25I,41 oo5,59

15 : 33 i = 2,200 14 : 33 i = 2,357 (A 28.02/05/08)13 : 33 i = 2,538 (A 28.03/06/09/

11/14/1618)A 28.01 = A 28.02/03/05/06/08/09/l 1 =2200...2600rpm 2200...2600rpm

up to MY 86 = approx. 2.7 Ifrom MY 87 to 90 = approx. 3.0 IMY 91 = 2.3 I*as of MY 92 = 1.9 IMultigrade transmission oil 75 W 90 to MIL L 2105 B orAPI classtication GL5Total capacity = approx. 8.01 (87 models onward,approx. 9.31). Capacity for fluid change with converter= approx. 6.01 (87 models onward, approx. 7.31) ATF Dexron II D

* refer to Technical Information No. l/91 of 08.3.91

0 Technlcal Data 30 - 0103Printed in Germany - XXXI. 1993


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928 General 30

TIGHTENING TORQUE FOR AUTOMATIC TRANSMISSION

Threadsescription Material TorqueNm (ftlb)

Location

Primary pumpto front cover Bolt M8

Bolt MlOxl

Bolt M8

Bolt M6

Plug M 27 x 1.5

8.8

10.9

8.8

10.9

-

20 (14)

14 (10)

13 19)

11 (8)

70 (51)

Plug(converter)Front coverto transmission caseSupport flangeto transmission casePlug(brake band B 1mount)Catch plate on rangeselector shaft Bolt M6

M6

M6

8.8

8.8

8.8

8 (6)

8 (6)

8 (6)

8 (6)

8 (6)

Bolteaf springto transmission caseStarter interlockand backup light switchto transmission case

1 Bolt

Range selector leverto shaft 1 Bolt M6

Bolt M6

8.8

8.8econdary pumpto transmission caseGovernor axial holdon shaft

Nut M6 8 6 (4.3)

Printed in Germany VI I I, 1984 Tightening Torques 30 0105


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30 General 928TIGHTENING TORQUE FOR AUTOMATIC TRANSMISSION

Location Description Threads Material TorqueNm (ftlt

Lower coverwith reinforcement plate

Bolt M5 5.8 4 (3)

Lower cover assy.to transmission case Bolt

M6 8.8 8 (6)

Plug (test connectionfor modulating, governorand operating pressure)

Plug M8xl - 13 (9)

Vacuum unit bracketKickdown solenoid valveEnd plate on valve bodyhousing

BoktSolenoidBolt

M6 8.8 8 (61M14x1.5 - 20 (14)M4 8.8 3.3 (2.3)

End plate on drivehousing

Bolt M4 8.8 3.3 (2.3)

Drive housing to valvebody housingValve body housingto transmission

Bolt M5 4.8 0.15(0.1 I)

Bolt M6 8.8 8 (6)

ATF filter to lower cover Bolt M5 8.8 4 (3)

d

030 - 0106 Tightening Torques Printed in Germany


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928 General Data 30a Tightening torques (automatic transmission)

Location

Threaded plug (ATF pan)ATF pan to transmission caseFront converter casing totransmission caseCarrier plate to converterRear transmission cas totransmission caseBearing assembly torear transmission caseFinal drive to transmissioncaseCollar nut (drive pinion)ATF filler tube to ATF panATF reservoir to ATF pan

Thread

MlOxlME

M8M8

M 10

ME

M 10M 26x 1.5M 24M6

* As of MY 92 (transmission type A28.18) = 450 Nm (332 ftlb),

Tightening Torque Nm (ftlb)

22 (12)8 (5.9)

23 (17)46 (34)

42 (31)

33 (24)

46 (34)380* (280)78 (58)6 (4.4)

0 Tightening torques (automatic transmission) 30-0107Printed in Germany - XXXI, 1993


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928 Torque Converter 32a TOOLS

No. Description Special Tool Remarks

1 Transmission holder 92162 Grip plate 93013 Mandrel 93104 Depth gauge - Standard tool

aPrinted in Germany - VIII, 1984 Removing and Installing Torque Converter 32 101


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32 Torque Converter 928REMOVING AND INSTALLING TORQUE CONVERTER

I-

i .-.-. -.-.-.- .-.-.-. ------/I-. Ii

y.


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928 Clutch, Automatic Torque Converter 32NC Description !tY.

Ii

4a

5

l I5

Mounting bolt

Panhead bolt 8

Washer 8

Front convertercasingTorqueconverter

lutomatictransmission

T6

1

1

1-

Removing Note When: Installing

Lift out carefullywith Special Tool9301

Tightening torque:46 Nm (34 ftlb)Tightening torque:23 Nm (17 ftlb)

Renew if badly wornor if particles arefound in ATFLubricate drive flangeand bearing pin withMoS multi-purposeire se. Placetransmission uprightand insert carefullyusing Special Tool9301. Noteinstallation depth.

Printed in Germany - XVI,1987 Removing and Installing 32 - 103Torque Converter


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32 Clutch, Automatic Torque Converter 928a/

NOTES ON REMOVING AND INSTALLING rI'

Removinql.Remove transmission. ./ ,. , J,/ -yp? pf./w / ;gzp,$2.Using Special Tool 9216, attachtransmission to assembly support.

6.Attach Soecial Tool 9301 totorque converter and carefullylift out converter.

3.Place transmission upright andworking through the openings in ~~the converter casing, removeconverter mounting bolts.!

4.Remove mounting bolts forconverter casing and removecasing. InstallinqNote:

5.Measure installation depth ofconverter and make a note forreassembly.

Up to '86 models = approx. 16 mm'87 models onward = approx. 28 mm

If the ATF smells burnt or if thefluid contains particles of padmaterial, torque converter and ATFcooler must be rinsed.If particles of metal are found inthe ATF pan, the torque convertermust be replaced. Rinsing will notremove all metal particles anddamage to the transmission mayresult.

32 - 104 Removing and InstallingTorque ConverterPrinted in Germany


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928 Clutch, Automatic Torque Converter 32l.Rinse torque converter withSpecial Tool 9310. To rinse, fillconverter with approx. 11 of

kerosine, insert the rinsing pinand use a hand drill to turn thepin at low speed. Then drainkerosine off through drain plug.Repeat rinsing 2 - 4 times untilthe kerosine drained from theconverter is clean.

2.Attach Special Tool 9301 totorque converter.

3.Coat drive flange and bearingpin of converter with MoS2multi-purpose grease.

4.Place transmission upright andcarefully insert converter,turning unit in both directionsto engage the teeth.

5.Check installation depth ofconverter.Up to '86 models = approx. 16 mm'87 models onward = approx. 28 mm

Printed in Germany - XVI,1987 Removing and Installing 32 - 105Torque Converter


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928 Automatic Transmission/Controls, Case 37REMOVING AND INSTALLING SELECTOR LEVER COVER FRAME

Removing

1. Remove selector lever grip and take offrubber boot.

2. Move selector lever to position 2 andpush rear locking bar forward against stopwith a suitable tool (e. g. scribe).

3. Move selector lever to position R,disconnect gate and push forward as far aspossible.

4. Push front locking bar forward against stopwith a suitable tool (e. g. scribe).

5. Move selector lever to position P andpress out cover frame carefully with asuitable screwdriver applied at the left rearcorner.

6. Move selector lever to position N andremove frame inclined toward rear.

Installing

1. Move selector lever to position 3.

2. Push gate in frame forward all the way,

3. Install cover frame in correct position andmove selector lever to position P.

4. Push cover frame forward and move rightside to correct installed position (this isdone by lifting left rear corner slightlyand pushing down on right side).

5. Push down on left rear corner until framefits in center console correctly.

Printed in Germane - VIII, 1984 Removing and Installing Selector Lever 37-101Cover Frame


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37 Automatic Transmission/Controls, Case 9286. Position selector lever between R and

P, disconnect gate on selector lever andpush forward.

7. Push front locking bar toward rear until itengages.

8. Move selector lever to position 3 andpush rear locking bar toward rear until itengages.

a9. Attach gate in selector lever, installrubber boot in correct position andinstall selector lever grip.

IO. Move selector lever in and out of allpositions and make sure that cover framefits properly.

a

a

A - Locked6 - Unlocked

37 - 102 Removing and Installing Selector Lever Cover Frame Printed in Germany


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928 Automatic Transmission/Controls, Case 37REMOVING AND INSTALLING SELECTOR LEVER CABLE

Removing

1. Unscrew ground strap of battery on body.

2. Remove selector lever grip and take offrubber boot.

3. Remove cover frame (see page 37 101).

4. Pull bulb holder carrier out of retainingclips.

5. Mark location of selector lever base forreinstallation and remove mounting screws.

6. Loosen intermediate muffler shield andpush aside as far as possible.

7. Disconnect selector lever cable on trans.mission lever and detach cable sleeve onbrackets.

23---7 -:+@*> : ---,iF /c-

8. Take off ball head, hexagon nut andmounting parts.

9. Attach tailing wire on cable and pull outselector lever base with cable by pullingforward at an angle.

10. Remove cable circlip on selector leverand detach cable sleeve on selector leverbase.a

Printed inGermany VIII, 1984 Removing and Installing Selector 37 103Lever Cable


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37 Automatic Transmission/Controls, Case 928Note:

Installing

1. Attach cable sleeve on selector lever base,tightening the hexagon nut carefully.

2. Push cable on to selector lever pin andinstall circlip.

3. Attach tailing wire, pulled forward duringremoval, on cable and pull cable towardrear, whereby one person should guide inthe selector lever base and a second personmust pull wire and cable.

4. Install selector lever base in correctposition (watching mark) and tightenmounting screws with 15 Nm/ll ftlb.

5. Install cover frame and selector lever grip.Place selector lever at N.

If light opening of gate and letter N arenot exactly opposite each other in coverframe, remove cover frame again and reposi-tion selector lever base in slots.

6. Mount selector lever cable on transmissionas specified.

7. Adjust selector lever cable (see page37 - 105).

37 - 104 Removing and Installing Selector Lever Cable Printed in Germany


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928 Automatic Transmission/Controls, Case 37ADJUSTING SELECTOR LEVER CABLE

1. Move selector lever to position N.

2. Place range selector lever on transmissionin N.

Note:Bolt for range selector lever must betightened for adjustments.

3. Adjust ball end on cable that attachment ispossible without tension.

lPrinted in Germany - VI II, 198 4 Adjusting Selector Lever Cable 37 - 105


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928 Automatic Transmission/Controls, Case 37REMOVING AND INSTALLING STARTER LOCKING AND BACKUPLIGHT SWITCH

Removing1. Disconnect selector lever cable.

- in

I q&..2. Remove bolt for range selector lever andpull off lever.

3. Unlock plug by turning white plastic ring(arrow) upwards in direction of arrow.

IWJ--- --I

4. Pry off plug carefully with two screwdrivers applied on cable outlet and bar.

/ --,fy!y;@-@+-q i3.-w-y..YQ;)(: .. 2 ? .--a? -- -,&+ of j,%gg$ -.:y g (5. Remove switch mounting screws and takeoff switch.

Installing1. Install switch with both mounting screws,but do not tighten.

Printed in Germany - VI I I, 1984 Removing and Installing Starter Locking 37.107and Backup Light Switch


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37 Automatic Transmission/Controls, Case 9282. Install range selector lever that lug on

switch engages. Move range selector leverto position N.

3. Install and tighten range selector leverscrew with 10 Nm (7 ftlb).

4. Adjust switch and connect plug (see page37 - 109).

5. Attach selector lever cable on selector rangelever.

a37.108 Removing and Installing Starter Locking andBackup Light Switch Printed in Germany


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928 Automatic Transmission/Controls, Case 37ADJUSTING STARTER LOCKING AND BACKUP LIGHT SWITCH

I. Insert locating pin made of 4 mm dia.welding wire for 4 mm dia. drill) throughlug into locating bore in switch housing.

2. Tighten switch mounting screws with10 Nm (7 ftlb) and pull out locating pin.

3. Press on plug and turn white plastic ringdown.

Printed inGermany VIII, 1984 Adjusting Starter Locking and Backup 37 - 109Light Switch


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928 Automatic Transmission/Controls, Case 37CHECKING ADJUSTMENT OF SELECTOR LEVER CABLE ANDSTARTER LOCKING/BACKUP LIGHTSWITCH

Move selector lever to position N. Runengine at fast idle speed.Pull up parking brake lever and press downon brake pedal for following tests.

6. Starting engine should only be possiblein p or ,TN,

7. Backup lights must be on in position R.

1. Move selector lever to position R. Enginespeed must drop as gear engages.

2. Move selector lever to position P. Enginespeed should increase as reverse geardisengages.

3. Repeat test in point I.

4. Move selector lever to position N. Enginespeed should increase as reverse geardisengages.

5. Move selector lever to position D. Enginespeed should drop as gear engages.

Printed in Germanv VIII, 1984 Checking Adjustment of Selector Lever 37 111Cable and Starter Locking/Backup Light Switch


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928 Automatic Transmission/Controls, Case 37a

NOTES ON REMOVING AND INSTALLINGRemovingl.Remove top and bottom halves of air

filter(l6-valve engines only)

2.Disconnect control cable at engine.

16-valve engines

!2B~~fi~

i) 1.

l 1 ,;.?y;-_ /F; .._1, ;\, ![: __.t ; i T ,..:s,Y., Ih.b, I yi 13

.e/.LI,,,j;,;,,;F T.;,- .-a .--~1

32-valve engines (up to '86 models)

. . ;.d .A,..;tr /#-., CA I

32-valve engines ('87 models onward)

3.Sever bowden cable behind threadedconnector.

4.Disengage control cable from trans-mission by pressing lockingtab of guide as arrowed (arrow A)and turning guide anti-clockwise(arrow B).

Printed in Germany - XVI,1987 Bowden Cable for Control Pressure, 37 - 113Removing and Installing(Service Solution)


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37 Automatic Transmission/Controls, Case 928

5.Carefully lift out guide.

6.Detach control cable from actuat-ing rod and pull out toward rear.

Installing:l.Carefully feed control cablethrough sleeve from rear.

2.Install clamp correctly andattach spherical head with hexnut.

A = Clamp3.Attach Bowden cable to transmission4.Adjust cable for control pressure(see page 37 - 115).

37 - 114 Bowden Cable for Control Pressure, Printed in GermanyRemoving and Installing (Service Solution)


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928 Automatic Transmission/Controls, Case 37CONTROL PRESSURE CABLE, ADJUSTING

Note:Correct adjustment of the Bowdencable for control pressure is vitallyimportant for faultless operationof the transmission.

l.Set idle speed.

2.Take up play in throttle cable.

3.Adjust spherical head of controlcable until cable can be installedwithout strain.

32-valve engines (up to '86 models)m6 .I - .%, -t.? .!r

h! .+d: 1-116-valve engines

. I

32-valve engines ('87 models onward)

Printed in Germany - XVI, 1987 Bowden Cable for Control 37 - 115Pressure, Adjusting


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928 Automatic Transmission/Controls, Case 37a TOOLS

No. Description

Universal transmission jack

Holding chain

Special Tool

-

9164

Remarks

Standard, e. g. from Hahn,Metallbau GmbH7012 Fellbach

aPrinted in Germany VIII, 1984 Removing and Installing Transmission 37.117


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37 Automatic Transmission/Controls, Case 928REMOVING AND INSTALLING TRANSMISSION

Removing 5. Disconnect control cable on throttlehousing.

1. Unscrew battery ground strap on body.

2. Disconnect multiple pin plugs in sparewheel well and pull out wires from below.

3. Remove upper and lower air cleanerhousings.

6. Disconnect oxygen sensor wire on centralfuse/relay panel and pull out from below(USA cars).

7. Remove engine air guide.

8. Remove complete exhaust assembly withshields.

9. Remove starter and suspend in suitableposition.

10. Drain ATF and remove reservoir.

11. Disconnect drive shafts on transmissionend and suspend on wire in horizontal

4. Remove upper air guide section. oosition.

a37 - 118 Removing and Installing Transmission Printed in Germany


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928 Automatic Transmission/Controls, Case 3712. Remove rear axle cross member/trans

mission suspension mounting bolts.

13. Support transmission on stabilizer withSpecial Tool 9164 (if necessary, lift trans-mission on transmission supportslightly).

14. Mark position of toe eccentric andrear axle cross member for reinstallationand remove entire rear axle.

15. Remove clamo bolt.

Printed in Germany VI I I, 1984 Removing and Installing Transmission 37 119

16. Disconnect selector lever cable on trans-mission lever and unscrew cable sleeveon holder and case.

17. Remove feed and return lines for ATFcooler. Plug open bores in case.

:A .-- I-,=,.I[ i --- I,, 9\ ., *;

. ~ .+,.&p~4+1: :-:;:y --_2; l? ,;~--.ky.,e.~ ~-,. 2fyqy-y.,-..!,.,,, ,g; : f ~, I __ ;

.;-~s;/~~~,, $ k&3i,. P i., +.,, :,--up -*h :

ffl3)

.x;-2


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37 Automatic Transmission/Controls, Case 92818. Pull off vacuum hose on modulatingpressure box.

19. Disconnect control pressure cable ontransmission. This is done by pushinglocking bar of guide in direction of arrow(arrow A) and turning guide counter-clockwise (arrow 6).

Pull out guide from above carefully.

Disconnect control cable on operatingrod.

a37 - 120 Removing and Installing Transmission Printed in Germany

20. Place universal transmission jack under-neath transmission and tighten rubberstrap.

21. Remove front and rear reinforcementplates.


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a

22. Lift transmission slightly and disconnectholding chain.

23. Lower transmission only far enough thatcentral tube/transmission mounting boltsand control cable mounting bolt can beremoved.

i$- -4\{- ~. 0 ; CT:: 91 ,. \.. Y*.: +I 1 it :.lib: t2 ,+ -. I a . z,:i- .-T, .- ., ! ..,,\? ,;;a _~1 =-;. .,. 124. Move central tube to installed position,

mount rear brace with two bolts and placea suitably thick block of wood betweencentral tube and brace.

25. Pull back transmission and lower carefully.

Installing

Note:Installation is in reverse order of removalprocedures, but also conform with followingpoints.

I. Place central tube in installed positionwith a suitably thick block of wood andcoat splines on central shaft with OptimolyHT.

-jx=.~--z;I!-.. ___ (,.


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37 Automatic Transmission/Controls, Case 9283. Install and slightly tighten accessible boltson central tube flange.

4. Lift transmission, remove block of wood andtake out brace again.

5. Lower transmission only far enough thatremaining bolts can be screwed in centraltube flange (tightening torque: 120 Nm/a7 ftlb).

6. Mount guide tube for control cable onconverter housing (tightening torque:8 Nm16 ftlb).

7. Push wire harness upwards throughopening in spare wheel well.

8. Lift transmission and hold in installedposition with Special Tool 9164.

9. Lower universal transmission jack.

10. Install rear axle and tighten all boltsexcept for two transmission mountbolts.

11. Lift transmission and disconnect SpecialTool 9164.

12. Adjust transmission suspension (seepage 37 - 123).

13. Mount transmission on cross member(tightening torque: 85 Nm/61 ftlb).

14. Check adjustment of selector lever andcontrol pressure cables, correcting ifnecessary.

a37-122 Removing and Installing Transmission Printed in Germanv


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928 Automatic Transmission/Controls, Case 37a ADJUSTING TRANSMISSION SUSPENSIONThe transmission mounts have to be adjustedto avoid tension in the transmissionsuspension and to also guarantee goodinsulation.

1

a 2

Install transmission and rear axle. Tightentransmission mount/transmission casemounting bolts with 85 Nm/61 ftlb.

Screw in cross member/transmission mountbolts several turns.

3. Lift transmission in middle of case farenough that there is a gap between bothtransmission mounts and the cross member.Measure this gap on both sides and take updifference with shims.

4. Place shims of pertinent thickness betweentransmission mounts and cross member,lower transmission and tighten transmissionmounts/cross member bolts with 85 Nml61 ftlb.

Note:After tightening the mounting bolts theremust be at least 1 mm clearance betweenthe transmission case and stop on side oftransmission mount.

Printed in Germany VIII, 1984 Adjusting Transmission Suspension 37-123


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H,-\ Lq--.~././ , - ,\a \f -.4 -*n,a.

aDescription

Support rail

Special Tool Remarks

- Standard(e. g. Kukko, Size 1)

aPrinted inGermany - VIII, 1984 Disassembling and Assembling Front 37-125Converter Housing


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37 Automatic Transmission/Controls, Case 928DISASSEMBLING AND ASSEMBLING FRONT CONVERTER HOUSING

( .(1

\

i \,?i/I 4i?

\,\

2 45 6 6

a

a

a

a37-126 Disassembling and Assembling Front Converter Housing Printed in Germany


40/277

928 Automatic Transmission/Controls, Case 37No. Description

1 Circlip2 Drive flange

my. Note When: SpecialRemoving Installing Instructions11 Press out Press into case

with grooved ballbearing (no. 4)

3 Spacer 14 Grooved ball 1 Press off with Heat to approx.bearing support rail, 120 C/250 F

e. g. Kukko. and push on tosize 1 drive flange

5 Circlip 16 Circlip 17 Grooved ball 1 Press out with Heat case to

bearing suitable piece approx.of pipe 120 C/250 F

and press inwith suitablepiece of pipe,supporting withdrive flange

1

Printed in Germany VIII, 1984 Disassembling and Assembling Front 37-127Converter Housing


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37 Automatic Transmission/Controls, Case 928DISASSEMBLING ~ANDASSEMBLlNG FRONT CXJfWEf?TEWfGUSING *Disassembling1. Remove c irclip and press out drive flange.

x_ IF- 77 ~~~-__- 1

.- L-i.- -

2. Press grooved ball bearing off of drive flangewith a support rail (e.g. Kukko, size 1).

I !1I ! 11i:ipiA- 1 j,i. SLl-x- -17 :T;i-.-7I 6; ,i II iI,

Assembling1. Install both circlips in converter housing.

2. Heat grooved ball bearing to about120 C/250 F and press bearing on driveflange against shoulder with a suitablepiece of pipe applied on bearing innerrace.

3. Heat converter housing to about 120 C/250 OF and press in drive flange withgrooved ball bearing against circlip.

3. -$.^; 1 r :

i /- +-..II / ._&: b\. . _. .z )-.-,/ ,7: 31 .- 0v ll

37-128 Disassembling and Assembling Front Converter Printed in GermanyHousing


42/277

l

928 Automatic Transmission/Controls, Case 374.Insert spacer sleeve and using a

suitable piece of pipe, pressfront deep-groove ball bearingover inner race until bearingcontacts circlip.

c- r-T -_ -~

-71 _~ 1%-1 -

m~~ p-7 T,.- .--- -- yj s i.. - ,:.;,I--?! -

Note:Place a suitable pressure piecebeneath the drive-flange bearing tokeep it from moving out as thefront bearing is pressed in.

Printed in Germany - XVI.1987 Disassembling and Assembling 37 - 129Front Converter Casing


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DISASSEMBLING AND ASSEMBLING FRONT CONVERTER CASING ('87 MODELS ONWARD)

37 - 130 Disassembling and AssemblingFront Converter Casing('87 Models Onward)XVI,1987 - Printed in Germany


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-No

-1

2

3

4

5

6-

Designation

Circlip

Drive flange

Deep-grooveball bearing

Spacer sleeve

Deep-grooveball bearing

Case

Qty

Press out

Pull off with puller(e.g. Kukko, size 1)

Removing Note when:Installing

Press in, after insert-ing deep-groove ballbearing (No. 5)Heat casing to approx.120C and press in asfar as possible witha suitable piece ofpipe.

Heat casing to approx.12O'C and press in witha suitable piece of pipe

Printed in Germany - XVI,1987 Disassembling and Assembling 37 - 130 aFront Converter Casing('87 Models Onward)


45/277


NOTES FOR ASSEMBLY AND DISASSEMBLY

Disassembling

1. Remove circlip and press outdrive flange. 2.Using puller (e.g. Kukko, size 1)pull deep-groove ball bearing offdrive flange.

rll1,; i 1 aI irz-i i &.,r -~--/

& i. . &f&- == !-, ,- ,-- f-k-7

-71 2;,! I+!i i! :

Assemblingl.Heat converter casing to approx.

120C and install both deep-grooveball bearings with spacer sleeve.

37 - 130b Disassembling and Assembling XVI,1987 - Printed in GermanyFront Converter Casing('87 Models Onward)


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2.Press drive flange in as far as itwill go.

Note:To prevent the deep-groove ballbearing (No.51 movino out as theflange is pressed, position asuitable piece of pipe against thebearing outer race as a support.

Printed in Germany - XVI,1987 Disassembling and Assembling 37 - 130 cFront Converter Casing('87 Models Onwards)


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No. Description

12

Pressure padMandrel

i

1

Special Tool I Remarks

9180/lP 254

aPrinted in Germany - VI I I, 1984 Removing and Installing Rear 37 131Transmission Case


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37 Automatic Transmission/ContruIs, Case 928REMOVING AND INSTALLING REAR TRANSMISSION CASE

9 6

+\2 I- .,;, 9 I3;

da,,;- ;p., I& _1 {jc /

s 5 ,- , ~_7T ji ~1, ,ii..k I

I(('iii' 1I.\iJi'

I1

L I a1[I /- -I I . ,r

5

37-132 Removing and Installing Rear Transmission Case Printed in Germanv


49/277

928 Automatic Transmission/Controls. Case 37

l

1 BoltM 10x55

2 BoltM 10x40

3 Washer4 Rear transmission

case5 Race

6 Gasket7 Seal

8 Sea I

9 Automatictransmission

Qty.-I

1

1

1

1

Note When:Removing InstallingTorque:42 Nm/30 ftlbTorque:42 Nm/30 ftlb

Insert afterinstalling caseReplace

Drive out withsuitable screw-driver

Replace, drivein to correctposition withSpecial Tool9180/l and coatsealing lip withATF

Drive out withsuitable screw-driver

Replace, drivein to correctposition withSpecial Tool9180/l and coatsealing lip withATF

SpecialInstructions

I

i

Printed in Germany VIII, 1984 Removing and Installing Rear 37-133Transmission Case


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37 Automatic Transmission/Controls, CaseREMOVING AND INSTALLING REAR TRANSMISSION CASE

928

a

Removing

fimkkive-si=&+e(see page 39 101).

2. Remove case mounting bolts.

A = Five M IO x 55 boltsB = Four M 10 x 40 bolts

Installing

I. Drive in inner seal to correct position withSpecial Tool 9180/I.

Note:Hold seal on special tool with a small amountof grease and drive in seal that sealing lipfaces automatic transmission.

2. Drive in outer seal to correct positionwith Special Tool 9180/l.

Note:Seal must be installed that its sealing lipfaces final drive.

a

a

a37 134 Removing and Installing Rear Transmission Case Printed in Germany


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928 Automatic Transmission/Controls, Case 370 TOOLS

mr

No. Description

1 Holder2 Grip3 Mandrel4 Depth gauge5 Centering pins6 Puller7 Pressing in tool

8 Pressure pad

Special Tool

921693019310-9321--

9180/l

Remarks

Standard tool

Standard toolMade locally(steel pipe 45 x 5 x40 mm with welded coverand 11 mm dia. bore)

aPrintedinGermany - VIII, 1984 Removing and Installing Rear Transmission 37-135


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37 Automatic Transmission/Controls, Case 928REMOVING AND INSTALLING REAR TRANSMISSION

2425 23

26r!---T (I J: ;y22\

i .-._.- .ir, .-.-. z.;.-.-.-.19

,-.-. ?-1

1811 12 13 14 15 16 ili

37-136 Removing and installing Rear Transmission Printed in Germany


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929 Automatic TransmisslonlControls, Case 37No. Des&nation Qty. T1 Bolt 42 Washer 43 Holder 14 Collar nut 1

5 Nut 1

6 Washer 17 Bolt 189IOI1I2

I3I4I5

-

WasherFinal driveO-ringShim S3Collar nut

Bolt 6Lock washerBeartng assembly withdrive pinion

61

Note:Installation

Torque:46 Nm I33 ftlb

Engage parking lock andunscrew

If necessary, pull out withs suitable puller

1

Torque:46 Nm / 33 ftlbTorque:46 Nm / 33 ftlb

Torque:46 Nm / 33 ftlb

Replace, coat with ATFDetermine thicknessTorque:380 Nm / 275 ftlb (as 01mod. 92 = 450 Nm, 36ftlb), and lockTorque:33 Nm I 24 ftlbHollow side faces flanglIf necessary, press inwith locally made tool

Removing and Installing rear transmlsslonPrimed in Germany -XxX& 1993

37 - 137


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No.

16

17

18

1920212223242526

A

Description

Shim

O-ring

O-ring

Panhead boltWasherATF reservoirMounting bolt

Panhead boltWasher

Converter casingTorque converter'

Mid-mountedtransmission

9

I

c

-ty. TX

11

2215

BB

11

1

Note When:Removing Installing

Note number andthickness forreinstallation

Lift out carefullywith Special Tool9301

Recalculate, ifnecessary

Replace, coat withATFReplace, coat withATFTightening torque:6 Nm (4.4 ftlb)

Tightening torque:46 Nm (34 ftlb)Tightening torque:23 Nm (17 ftlb)

Rinse with SpecialTool 9310. Installwith Special Tool9301.

* Note installation depth:Up to '86 models = approx. 16 mm'87 models onward = approx. 28 mn

37 - 138 Removing and InstallingMid-mounted Transmission XVI,1987 - Printed in Germany


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928 Automatic Transmission/Controls, Case 37REMOVING AND INSTALLING REAR TRANSMISSION

Removing

1. Remove transmission.

2. Mount transmission in assembly stand withSpecial Tool 9216 and drain final drive oil.

3. Engage parking lock and remove collar nutfor drive pinion.

4. Remove bearing assembly mounting boltsand pull off bearing assembly (use asuitable puller, if necessary).. c,b-1 M-7-T

m. I

, 6 ? /CT%?,r: i;rr ,@k&y;:~2,d \I\..:; $ ,!;r +f-- 1. /

4

A = Bolt 10 x 30 with centering bore

5. Position transmission upright and removeconverter mounting bolts through openingsin housing.

6. Remove converter housing mounting boltsand take off housing.

7. Measure installed depth of converter(about 16 mm) and note value forreinstallation.

-y--JT(& 14 p$.N. i;+J;:a 1 -- J

rfb~ I T ;

8. Mount Special Tool 9301 on torque con-verter and lift out converter carefullv.

PrintedinGermany - VIII, 1984 Removing and Installing Rear Transmission 37.139


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37 Automatic Transmission/Controls, Case 928Installing

Note:The outer seal on the rear transmissionbetween the transmission case and finaldrive could be missing due to manufacturingconditions.

1. Drive in outer seal (if not already installed)to correct position with Special Tool9180/i.

Note:Outer seal must be installed that sealing lipand spring supporting the sealing lip facefinal drive.

2. Mount Special Tool 9301 on torqueconverter.

3. Coat drive flange and bearing journal ofconverter with a multi-purpose greasecontaining MoS, additives.

4. Position transmission upright and installconverter carefully, while turning con-verter back and forth until splines mesh.

5. Check installed depth o f converter (about16 mm).

37 140 Removing and Installing Rear Transmission Printed in Germany


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928 Automatic Transmission/Controls, Case 37Note: 7. Install shims of determined thickness andbearing assembly on output shaft.If ATF smells burnt or contains metalparticles, torque converter and ATF coolermust be flushed. er If ATF sump contains metal particles, torque /q?+- Iconverter has to be replaced. Metal particlescould not be completely removed by flushing ,q ,,/ /, rand would lead to transmission damage.

f--Y-- Y, :: ,I ~ (11 I,

l \,;: I/it

6. Determine thickness of shims for bearing L,,assembly. Measure distance from tapered AI /4 Ari

roller bearing surface to bearing flange -isurface with a depth gauge (for example: -

,, I 134.55 mm). Since the distance specified bydesign is only 34 f 0.05 mm, shims havinga thickness of 0.55 mm must be installed. Note:

Use Special Tools 9321 and a locally madepressing in tool to make installation easier.

aExample:

f--y7ef I?--7) c;,i -ir, / - 1. ;; r I; k&T;\ , d; 1-:/ (g- I/-;.-;


58/277

48 AutomatlcTransmlssion/Controls, Case 920 a8. Tighten flange nut for drive pinion to speci-

fied torque and lock by upsetting the flange

9. Adjust drive pinion and ring gear (see page39 - 125).10. Install transmission and check adjustment

of selector lever and control pressure ca-bles.

37-142 Removlng and lnstalllng reartransmlsslon aPrinted in Germany - XXXI, 1993


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928 Automatic Transmission/Controls, Case

TOOLS

a

P-l@@\: 2c

f$-- 8 -1.---+--P

\1 ( 3~)YI^. 7 /-

DesignationHolderAssembly supportMandrelMeasuring bridgeDepth gageCirclip pliersSpacer sleeveMeasuring deviceCentering pins

Special Tool Remarks9216 I931691199313

931293209321

CommerciaCommercia lly availablellv available(e.g. Hazet"1847 - 2)

aPrinted in Germany - XVI,1987 Disassembling and Assembling 37 - 143Transmission


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DISASSEMBLING AND ASSEMBLING TRANSMISSION

Disassemblingl.Attach transmission to assembly 5.Unscrew combination bolts andsupport with Special Tool 9216. remove ATF pan with ATF reservoir.

Z.Remove final drive with bearingassembly (see page 39 - 101).3.Remove rear transmission case(see page 37 - 131).

4.Remove front converter casing andconverter (see page 32 - 101).6.Unscrew cross-recess screws andremove filter.

a

37 - 144 Disassembling and Assembling Transmission Printed in Germany


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928 Automatic Transmission/Controls, Case 3719.Unscrew hex bolt and removedrive-range selector lever.

ZO.Remove starter-interlock switchafter unscrewing mounting bolts.

~~ ----;-..

/

.-a

r 7

3,,.\- \ c1

6--;

:j d-1\> &$ !

;-7.*., -,I s$ , p$ 4.

,,..

Zl.Remove vacuum-control unit afterunscrewing socket-head bolts.

22.Remove pressure unit B 1 andmodulating pressure control valve.

Printed in Germany - XVI,1987 Disassembling and Assembling 37 - 147Transmission


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37 Automatic Transmission/Controls, Case 92823.Remove kickdown solenoidvalve and injector tube.

24.Remove parking lock with paw1and expander spring.

25.Remove plastic guide and roller.

p y pLypc%z-) 7;,,=,A$

;

a

38 - 130 b Disassembling and AssemblingShift Valve Casing ('87 Models Onward) Printed in Germany


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928 Automatic Transmission/Gears, Control 38

No.l..,18

19

l 2o21

22

23

24

25

26

27

DesignationValve ball(dia. 5.5 mm)

Plastic valve(light, withoubore)

Throttle checkvalve

Check valve

Shift pin,lubricatingpressureThrottle

Valve

Shift pin

Valve

Throttle*(with spring)

t

NY.18

Note When:?emoving

:aptive

InstallingInsert taper spring withlarge diameter downwardbeneath ball No. 5.

Insert right way round,do not mix up with valvewith bore

Install with spring

Install with spring

Install with spring

Install with spring

* At the start of series production the throttle was installed in some casesand was later discontinued without replacement.

aPrinted in Germany - XVI,1987 Disassembling and Assembling 38 - 130 cShift Valve Casing('87 Models Onward)


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NOTES FOR DISASSEMBLY AND ASSEMBLY

Disassembling

Note:It is essential to maintainabsolute cleanliness during allwork on the shift valve casing. Ifpossible, spread a plastic sheet onthe workbench beneath the parts(moleskin cloths are particularlysuitable). After disassembly, washall parts and blow through withcompressed air.l.Remove plastic valve and chipscreen.

rn~.- -r-j

.y.mz,. - . Iz----r E~,z$$;~s;q~Lkz&q~~&~~rc-.-g=&J ,T,sl&g ~-ZI~;r_p&L~3~~~:g-_+-& G HL?-cQ *,

-2 ..I .fP*- - I.-l,, I+?/3 - ii T e;

2.Remove both mounting screws(arrowed).

3.Hold shift valve casingsensor housing togetherover.

andand turn

4.Carefully lift off sensor housingwith back plate

b B

A - Plastic valveB - Check valveC - Shift pinD - Lock valve K 1E - Chip screen

. . n cA

5.Remove all valves and balls.

38 - 130 d Disassembling and AssemblingShift Valve Casing ('87 Models Onward) Printed in Germany


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928 Automatic Transmission/Gears, Control 38Assemblingl.Place all valve balls and valves inshift valve casing (see explodeddrawing).2.Install lubricating-pressurevalve, overpressure modulatingvalve and bleed valve Kl insensor housing.

A = Lubricating pressure valve(captive)B = Overpressure modulating valve(captive)C = Bleed valve (captive)

3.Carefully place back plate onshift valve casing and check thatvalve ball (arrowed) is in itsinstallation position.

4.Place sensor housing on shiftvalve casing.

5.Hold shift valve casing andsensor housing together and turnover.

6.Insert both screws (do nottighten).

Printed in Germany - XVI,1987 Disassembling and Assembling 38 - 130 eShift Valve Casing('87 Models Onward)


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Note:Tighten screws so that housing andcasing can still be moved againsteach other.

7.Insert plastic valve (yellow)in casing with bore and chipscreen right way round.

A = Plastic valveB = Chip screen

a38 - 130 f Disassembling and AssemblingShift Valve Casing ('87 Models Onward)

Printed in Germany


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928 Automatic Transmission/Gears, Valve Body 38REMOVING AND INSTALLING LOWER COVER

Removing

1. Remove shift valve housing.

Installing

1. Check for proper seating of temperatureorifice, plastic valve, filler and oildeflector.

2. Remove ATF filter.

3. Remove holder and leaf spring.

0 w;--6. w-ry . .-* .m-. ..---

4. Remove combination bolts and take offcover with oil tube.l

ew?y 7;'Sq..,'


128/277

38 Automatic Transmission/Gears, Valve Body 9282. Mount lower cover, guiding oil tube into

bore.

3. Install combination bolts, but do nottighten (tighten bolts with 8 Nm/6 ftlbonly after installing the shift valve housing)

4. Mount leaf spring with holder and installbolt but do not tighten (tighten bolt with8 Nm/6 ftlb only after installing the shiftvalve housing).

5. Install shift valve housing and tightencombination bolts with 8 Nm/6 ftlb(including bolts on lower cover).

6. Install ATF filter and tighten phillipsscrews with 4 Nm/3 ftlb.

l38 - 132 Removing and Installing Lower Cover Printed in Germany


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928 Automatic Transmission/Gears, Valve Body 38a DISASSEMBLING AND ASSEMBLING LOWER COVER

2

.A.---...

we r\ / .* ._, 1 -,~_/

II

f r

* ,~ - . .

Printed in Germany VI I I, 1984 Disassembling and Assembling 38-133Lower Cover


130/277

38 Automatic Transmission/Gears, Valve Body 928

I

1IIII

No. Description

1 Oil tube2 Injector

my. Note When: SpecialRemoving Installing Instructions11 Squeeze tabs Install in correcttogether and positionremove

3 Bolt 4 Torque:8 Nm/6 ftlb4 Cover 15 Gasket 1 Replace,if necessary6 Transfer plate 17 Filter screen 28 Valve 1 Position correctly,check for tightfit9 Holder 1 Position correctly

IO Plug 1I1 Spring 1I2 Shift valve 1 Install with ATFsecondary pump13 Circlip 114 Sleeve 115 Shaft 116 Spring 117 Sleeve 118 Circlip 1I9 Blocking valve 1 Coat with ATF20 Housing 1

a

a38-134 Disassembling and Assembling Lower Cover Printed in Germany


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928 Automatic Transmission/Gears, Valve Body 38a DISASSEMBLING AND ASSEMBLING LOWER COVER

Note:Absolute cleanliness is essential for any workon shift valve housing and lower cover.Work should be performed with a plastic lineron the workbench whenever possible. Neveruse cloths losing lint.

1. Squeeze both tabs together and removeinjector.

2. Remove filter screens and valve.

3. Take off circlip. Remove blocking valvewith spring and shaft.

Assembling

1. Install shift valve secondary pump withspring and plug, and secure with holder.

-%i=s~~,.~*~ - .. - _ -- -k_- I*.,. - ::I Ic.--~&zi- :I;-* , s ri,. .A: /1 p+ &,*I j-p$,~,~p ,i

38-166 Disassembling and Assembling One-way Clutch Printed in Germany


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928 Automatic Transmission/Gears, Valve Body 383. Place outer race of one-way clutch on inner

plate carrier and install roller cage incorrect oosition.

4. Push cylindrical rollers against springs andapply Special Tool 9322 with bend facingout.

5. Install one-way clutch inner race whileturning in direction of arrow.

6. Remove Special Tool 9322.

7. Install shim.

Note:Install O-ring only after checking axial playof one-way clutch.

Printed in Germany - VI I I, 1984 Disassembling and Assembling One-way Clutch 38-167


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38 Automatic Transmission/Gears, Valve Body 9288. Install support that pin engages in bore

(arrow) of one-way clutch outer race.

9. Place shims (if available) on outer race ofone-way clutch and install connectingcarrier on one-wav clutch.

10. Install snap ring and press into groovewith a screwdriver.

ffq yy/p4* , (_-. - . b,; me.;:. :,. I _ 1-4*

Checking and AdjustingOne-wav Clutch Axial Play:

1. Check play between one-way clutch andconnecting carrier with a feeler gauge.

I,

2. Adjust play to 0.05 0.2 mm withshims.

3. Install O-ring,

38 168 Disassembling ans Assembling One-way Clutch Printed in Germany


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928 Automatic Transmission/Gears, Valve Body 38a TOOLS

2ff+-+----+b , .-.1!

3 ;,-_-

l ,,/ - j \ . ./z1,j\ ??+-\

tNo. Description Special Tool Remarks

1 Assembly tool 93152 Assembly sleeve 93173 Assembly sleeve 93184 Feeler blade gauge - Standard tool

-

Printed in Germany VIII, 1984 Disassembling and Assembling 38 - 169Clutch K 1


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38 Automatic Transmission/Gears, Valve Body 928DISASSEMBLING AND ASSEMBLING CLUTCH K 1

L -.-.m.-.-.-.-.- .m.m.s. 1.

i i 5 (38-170 Disassembling and Assembling Printed in GermanyClutch K 1


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a-

a

928 Automatic Transmission/Gears, Valve Body 38No. Iescription

;nap ring

I(uter platenner plate2.1 mm thick)

Iuter plate

5 ~ Outer plate~ 12.0 m m thick)

I IDiaphragm spring

I!Snap ring

Diaphragm springSpring

Qty, TX

1

5

4

1 I

Removing Note When:InstallingRedeterminethickness,if necessaryCheck for burntspots and bendil

Check for burntspots and wear.If less than 2 mrthick, replace.Place in ATFabout 1 hourbefore installingCheck for burntspots andbending

Check for burntspots andbendingPosition correctthat curvedsurface facespistonInstall with

Special Tool 9315 Special Tool 93checking forcorrect fit

Vote quantityfor reinstallation

w

!3

n

Iv

15. I

SpecialInstructions

4.5 or 5.0 mmthick (optionato adjust play)

3.0 or 3.5 mmthick(optional toadjust play)

aPrinted in Germany VIII, 1984 Disassembling and Assembling 38-171Clutch K 1


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38 Automatic Transmission/Gears, Valve Body 928No.

1 13

10

11

12

Description

Piston

Seal

Seal

Plate carrier

Qty. Note When:Removing Installing1 Install with

Special Tools9317 and 9318

1 I Position correctlv.coat with ATF Position correctly.coat with ATF

L

SpecialInstructions

a38. 172 Disassembling and Assembling Printed in GermanyClutch K 1


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928 Automatic Transmission/Gears, Valve Body 38l

DISASSEMBLING AND ASSEMBLING CLUTCH K 1

Disassembling

@

1. Apply Special Tool 9315 on diaphragmspring and tighten until snap ring can beremoved.

2. Remove diaphragm spring and springs

Note:The quantity of springs for clutch piston willvary. If new springs are required, the samequantity of springs must be installed.

Assembling

1. Install seals in piston that sealing lips facedown (direction of arrow).

2. Apply Special Tools 9318 and 9317 inouter plate carrier.

3. Install piston carefully and press intoouter plate carrier without canting.

Note:Coat seals and sliding surfaces on SpecialTools 9318 and 9317 with ATF.

Printed in Germany - VI I I, 1984 Disassembling and Assembling Clutch K 1 38 173


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38 Automatic Transmission/Gears, Valve Body 9284. Install springs in piston and place on

diaphragm spring, whereby each springmust be centered by a guide pin.

5. Apply and tighten Special Tool 9315.

6. Install snap ring and release special tool.Check that snap ring fits properly,

7. Install diaphragm spring with curvedsurface on piston as shown in figure.

1 = Diaphragm spring

8. Assemble set of plates as shown in layoutdrawing and install in plate carrier.

Note:New inner plates must be placed in ATF about1 hour before installing.

Checking Play (0.7 to 1.2 mm) of Clutch:

1. Push up snap ring around entire peripherywith a suitable screwdriver.

t /

a

2. Check play A with a feeler gauge blade.

a

38 174 Disassembling and Assembling Clutch K 1 Printed ,n Germanv


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928 Automatic Transmission/Gears, Valve Body 38Note:Play A can be adjusted with a snap ringwhich is available in 3 thicknesses(2.0 / 2.5 / 3.0 mm). However, if thespecified play cannot be reached with snaprings, the center outer plates must also beused for adjusting.

Printed in Germany VIII, ,984 Disassembling and Assembling Clutch K 1 38-175


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TOOLS

No. Description

1 Assembly tool2 Assembly sleeve3 [ Feeler blade gauge

I

Special Tool

93159317-

Remarks

Standard tool

Printed in Germany VI I I, 1984 Disassembling and Assembling 38 177Clutch K 2


170/277


i

\

*--7r-9-l-l . ,. , i.J a

2 3 5

38-178 Disassembling and Assembling Printed in GermanyClutch K 2


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928 Automatic Transmission/Gears, Valve Body 38TNo.

FDescription

Snap ring

2 Outer mate

3 Inner plate(2.1 mm thick)

4 Outer mate

5 Outer plate(2 mm thick)

6 Snap ring

8Diaphragm springSpring X

1I19 istonL

Qty. Note When:Removing

Iqemove with: pecial Tool 9315

I!N

fclate quantityx reinstallation

InstallingRedeterminethicknessif necessaryCheck for burntspots and bending

Check for burntspots and wear.Replace ifthickness is lessthan 2 mm.Place in ATFabout 1 hourbefore installing.Check for burntspots andbending

Check for burntspots and

Install withSpecial Tool 9315Check for correctfit

.I

Install withSpecial Tool9317

I

SpecialInstructions

1.5or5.0mmthick:optional toadjust play)

3.0 or 3.5 mmthick(optional toadjust play)

!Printed in Germany VIII, 1984 Disassembling and Assembling 38 179Clutch K 2


172/277


11I

Description ~~~~ote When:

Seal

Sea I

Plate Carrie1

I Removing Instal!ing1

1

1

-

Position correctly,coat with ATFCoat with ATF,must not turnon its own

SpecialInstructions

38 180 Disassembling and Assembling Pttnted iv GermanvClutch K 2


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Disassembling

1. Apply Special Tool 9315 on diaphragmspring and tighten until snap ring can beremoved.

2. Remove diaphragm spring and springs

Note:The quantity of springs for clutch piston willvary. If new springs are required, thequantity must not be changed.

2. Install seal in piston that sealing lip facesdown (direction of arrow).

3. Apply Special Tool 9317 on plate carrier.Assembling

1. Install seal and make sure that seal doesnot turn on its own.

PrinTed in Germany VIII, 1984 Disassembling and Assembling Clutch K 2 38 181


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38 Automatic Transmission/Gears, Valve Body 9284. Install piston in plate carrier by turning

slightly. Do not cant the piston.

v t% A_4 .*a

Note:Coat seals and sliding surfaces on special toolwith ATF.

5 Install springs in piston and mountdiaphragm spring that each spring iscentered by a guide pin.

6. Apply and tighten Special Tool 9315.

7. Install snap ring.

8. Assem ble set of plates as shown in layoutdrawing and install in plate carrier.

Note:Place new inner plates in ATF about 1 hourbefore installing.

Checking Play (0.7 to 1.2 mm) of Clutch:

1. Push up snap ring around entire peripherywith a suitable screwdriver.

38. 182 Disassembling and Assembling Clutch K 2 Prfnted m Germanv

a


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928 Automatic Transmission/Gears, Valve Body 382. Check play A with a feeler gauge blade.

Note:Play A can be adjusted with a snap ringwhich is available in 3 thicknesses(2.0 / 2.5 / 3.0 mm). However, if specifiedplay cannot be reached with snap rings, thecenter outer plates must a lso be used foradjusting.

Printed in Germanv VI I I, 1984 Disassembling and Assembling Clutch K 2 38 183


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-

a

928 Differential/Transaxle System 39TOOLS


1 Holder 92162 Centering pin 93213 Puller - Standard tool4 Pressing in tool - Made locally (45 x 5 x 40 mm

steel pipe with welded coverand 11 mm dia. bore)

5 Depth gauge I - Standard iool

aPrinted in Germany VI I I, 1984 Removing and Installing Final Drive 39-101


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39 DifferentiaI/Transaxle System 928 aREMOVING AND INSTALLING FINAL DRIVE

r'-'- .-.- .-.-. - .-.-.-. - .-.-. -.-.-I 14x3- +-IIi

IL

L3 c

,, /i,r '2:,; !j&-;

! f,\-1,, ( ;118 16 15 14 13 1'1 Q

j

39-102 Removing and Installing Final Drive Printed in Germany


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928 Differential, Transaxle System 39No. Description

1 Bolt2 Washer3 Holder4 Collar nut5 Nut6 Washer7 Bolta Washer9 Final drive

10 O-Ring

I1 Shim 5s

12 Flange nut

13 Bolt14 Lock washer

Note whenQty. Removing Installing

4 Torque: 49 Nm / 33 ftlb411 Torque: 46 Nm / 33 ftlb1 Torque: 46 Nm/ 33ftlb12 Torque: 46 Nm / 33 ftlb211 Replace, coat with ATF,

check for correct fitX Note quantitiy and thick- Redetermine, lf

ness for reinstallation necessary1 Engage parking lock and Tighten to 380 Nm I

unscrew 275 Rib and lock6 Torque: 33 Nm / 24 ftlb6 Hollow side faces flangt

* As of MY 92 (Transmission type A 28.18) q 450 Nm (332 ftlb.)a

a Removing and installing final drivePrinted in Germany -XxX& 1933

39 - 103


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39 Differetial/Trasaxle System 928NO.

16

18

Description

Bearing assemblywith drive pinion

Shim

O-ring

O-ring

19 AutomaticI transmission

Qtv Note When:Removing InstallingIf necessary. If necessary,pull out with press in withsuitable puller locally made toolNote quantity Redetermine,and thickness for if necessaryreinstallation

Replace.coat with ATFReplace,coat with ATF

1

SpecialInstructions

39 104 Removing and Installing Final Drive Prtnted in Germany


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928 Differential/Transaxle System 39a

REMOVING AND INSTALLING FINAL DRIVE

Removing Installing1. Remove transmission.2. Mount transmission on assembly stand with

Special Tool 9216 and drain final drive oil.

1. Install quantity of shims noted duringremoval or shims of redetermined thicknessand bearing assembly on drive pinion.

3. Engage parking lock and remove collar nutfor drive pinion.

4. Remove mounting bolts for bearingassembly and pull off bearing assembly(if necessary, use a suitable puller).

4k ..-i,, \Qf5;? .- I- j-1 +& / yb

p&p+#; /.!.

A = M 10 x 30 bolt with centering bore

Note:Use centering pins, Special Tool 9321, and alocally made pressing in tool to makeinstallation easier.

m -;--*-- -& .,,. ,:j?, K! ~--Y-=-

; r---3,:,5 $$ il ii

()I, iN , (--$q-,\&j/ i 1! + *rem-L /j

1 = Bolt from Special Tool 91482 = Washer

Printed in Germany . VI 11, 1984 Removing and Installing Final Drive 39-105


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39 Differential, Transaxle System 929 a2. Tighten flange nut for drive pinion to speci-fied torque and lock by upsetting the flange.

9 a

39-106 Removing and InstallIng flnal drive aPrinted in Germany - XXXI. 1993


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928 Differential/Transaxle System 39eTOOLS

a0INo. Description Special Tool Remarks1 Pressure pad 91472 Pin - From P 254

aPrinted in Germanv - VI I I, 1984 Disassembling and Assembling Final Drive 39.107


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39 DifferentiaI/Transaxle System 928DISASSEMBLING AND ASSEMBLING FINAL DRIVE

r,,~; 7 l5Jr; ;., \+ I /r- 2; dL4, Y,

,--IrC

127

235I. -.. I -_

,

I8 8 20

1

,

:

a

I

-X.- a\-

a39-108 Disassembling and Assembling Final Drive Printed in Germany


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928 Differential/Transaxle System 39

a

-.No. Description

1 Bolt

Qty. Note When: SpecialRemoving Installing Instructions

12 Torque:23 Nm/17 ftlb2 Washer 123 Holder 14 Cover 15 Gasket 1 Replace6 Plug 1 Torque:22 Nm/17 ftlb7 Plug 1 Torque:(with magnet) 22 Nmfl7 ftlba Shield 19 Bolt 2 Torque:

46 Nm/33 ftlbIO Joint flange 2I1 Bolt 12 Torque:

23 Nmll7 ftlb12 Washer 1213 Holder 1I4 Bearing cap 2 Mark for Must be installed

reinstallation same side2 Replace, coat

with final driveoil

lPrinted in Germany VIII, 1984 Disassembling and Assembling Final Drive 39 109


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1

1ii

L

Jo. Description

16 Shim

Qty. Note When: SpecialRemoving Installing instructions

X Note quantity Redetermine,and thickness if necessaryon each sidefor reinstallation

I7 Seal 2 Drive out with a Drive in withsuitable screw- Special Tooldriver 9147

I8 Tapered roller 2 Mark for Install in samebearing outer race reinstallation bearing cap.

Heat bearing capto 100 C/212 OFand drive in witha suitable pressurepad

I9 Differential 1 Adjust,if necessary

!O Vent 1!I Case 1

a39 110 Disassembling and Assembling Final Drive Printed in Germany


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928 Differential/Transaxle System 39DISASSEMBLING AND ASSEMBLING FINAL DRIVE

Disassembling Assembling

1. Clamp final drive in a vise with a suitablefixture.

1. Install shield

.- - .?. ~. s. -* k _ L L-, :f I ,s$;, fp+-ff?g-..

, ? _,- ! :t A ! - rl -.- t .- II I .-4

-A,MY- _ ,.-,6i -.

A = Iron angle 2. Drive in seal for joint flange with SpecialTool 9147.

2. Remove bolt for joint flange and take off ~- ~- -flange.

/ ! /--j bpi.&h

\: /; AA)

Printed in Germany VIII, 1984 Disassembling and Assembling Final Drive 39 111


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Differential/Transaxle System 39

~~.__ _---- ?/ I-. -_,

: -~ .?qe..

: \ .) i ,,:;I..-:.

j .( I#-91 i f. ,

i2 2

+ &v-+


1 Pressure pad P 2632 Puller - Standard tool3 Pressure pad P 264 b

Printed in Germany - VI I I, 1984 Disassembling and Assembling Differential 39 - 113


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39 Differential/Transaxle System 928 lDISASSEMBLING AND ASSEMBLING DIFFERENTIAL

.< \&Y CY


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928 DifferentiaI/Transaxle System 39

-

a

lo. Description Qty. Note When: SpecialRemoving installing Instructions1 Tapered roller 2 Pull off with Drive on withbearing inner race a suitable puller Special Tooland Special P 264 b

Tool P 2632 Circlip 13 Magnet carrier plate 14 Lockplate 6 Replace5 Bolt 12 Threads must

be dry andgreaseless.Torque:150 Nm/108 ftlb

6 Ring gear 1 Tapped holesfor ring gearbolts must bedry andgreaseless.Note pairnumber. Adjustif necessary

7 Pin 18 Differential pin 19 Spacer * 1

IO Needle cage * 2I1 Small differential 2 Coat oval surfacegear with MoS, paste.

Replace onlyin pairs

a Printed in Germany XX, 1988 Disassembling and Assembling Differential 39.115


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39 DifferentiaI/Transaxle SystemDescription Qty.

12

131415

Large differentialgear

Threaded piece

WDifferential case

Note When:Removing Installing

Coat ovalsurface withMoS, paste.Replace only inpairs

SpecialInstructions

* Modified needle-bearing mount as from Model 86. The spacer sleeve is no longer requiredthanks to the new needle-roller assembly.

a

a39 116 Disassembling and Assembling Differential Printed in Germany


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928 Differential/Transaxle System 39a DISASSEMBLING AND ASSEMBLING DIFFERENTIAL

Disassembling

1. Pull off tapered roller bearing inner racewith.a suitable puller and Special ToolP 263.

2. Coat oval surface of differential gears withMoS, paste.

3. Install large differential gears with press-fit threaded plates through large openingin differential case and hold with jointflanges.

Assembling

1. Install ring gear on case and tighten ringgear bolts to 150 Nm/lOB ftlb. Slide lock-plate into groove of bolts, squeeze togetherat front with a pliers (to unite lockplatewith bolt) and bend down over a hexagonsurface to lock.

aPrinted in Germany VIII, 1984 Disassembling and Assembling Differential 39-117


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39 Differential/Transaxle System 9284. 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----me:pL ~/

f=i 1,f.. ___

d ./

. .-... ,..-:- ._ c.-U i ;

I-*-- \,.+ .~.3:

CA b?! ,A-\ -,-d; 1:

*:--z,y 3 C. ;.

*


193/277

928 DifferentiaI/Transaxle System 39a

TOOLS

I+@@& .yh-?A ?,*.~:1.. r-7 PA!!@@< -f--b , ./p-4 ,/.~---.2 /*ah

No. Description

i

1 Puller2 Depth gauge

Special Tool

--

e. g. Kukko, size 2Standard tool

Printed in Germany - VIII, 1984 Disassembling and Assembling 39 119Bearing Assembly


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39 Differential/Transaxle System 928DISASSEMBLING AND ASSEMBLING BEARING ASSEMBLY

+-r!// T ? \.~

i

+Yp)fT \ \,x3 l?. \a

39-120 Disassembling and Assembling Bearing Assembly Printed in Germany


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928 Differential/Transaxle System 39No. Description

1 Bearing flange

Qty. Note When: SpecialRemoving Installing Instructions

1 For replacementsonly availableas complete part(positions 1 to 4)

2 Tapered roller 1 Heat to approx.bearing inner race 120 C/250 OF

and install3 Adjusting ring X4 Tapered roller 1 Heat to approx.

bearing inner race 120 C/250 o Fand install

5 Pinion 1 Press out with Note pair number.a piece of Adjust ifsuitable pipe necessary

6 O-ring 1 Replace, coatwith ATF

Printed inGermany - VIII, 1984 Disassembling and Assembling 39 - 121Bearing Assembly


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39 Differential/Transaxle System 928DISASSEMBLING AND ASSEMBLING BEARING ASSEMBLYDisassembling1. Press out pinion with a piece of suitablepipe.

-. -i_

2. Press off tapered roller bearing inner racewith a special tool (e. g. Kukko, size 2).fz,- -.- - F-7 2/ ,--- >-~.

Assembling

Note:Bearing flange is only available as a completeunit (with tapered roller bearings andadjusting ring) for replacements.

1. Heat tapered roller bearing inner races toapprox. 120 C/250 OF and install.

2. Press on assembled bearing with a piece ofsuitable pipe (approx. 5 tons force).

5-23.

39-122 Disassembling and Assembling Bearing Assembly Printed in Germany


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928 Differential/Transaxle System 393. Lubricate both tapered roller bearings with

final drive oil through oil feed bore afterinstallation.,//(42/f,,( 7i ci 2

4. If necessary, determine thickness of shimsfor bearing assembly.

Determining Thickness ofShims for Bearing Assembly

Note:The adjustment of bearing assembly isimportant for axial play of automatictransmission.Consequently the thickness of shims has tobe determined again after repairing orreplacing a bearing assembly.

Use a depth gauge to measure distance fromtapered roller bearing surface to tearingflange surface (for example: 34.55 m m).

Since the design calls for a distance of only34 + 0.05 mm, a shim 0.55 mm thick has tobe used.

II

. .

Example:34.55 mm actual distance (measured)

- 34.00 mm nominal distance (specified)0.55 mm thickness of shims

Printed in Germany - VI I I, 1984 Disassembling and Assembling Bearing Assembly 39-123Determining Thickness of Shims for BearingAssembly


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TOOLS

8

i

No. Description Special Tool Remarks1 Master gauge VW 385/l2 Centering plates VW 385/43 Master plunger VW 3851144 Dial extensionauge (30 mm) 93235 Adjusting gauge VW 3851306 Dial gauge - Standard, 3 mm range7 Dial gauge - Standard, 10 mm range8 Feeler gauge - Standard, 0.05 to 1 .O mm9 Clamping sleeve 9145

10 Adjusting fixture VW 5211411 Master lever VW 38812 Dial holderauge VW 38713 Lever - Made locally

PrintedinGermany - VIII, 1984 Adjusting Drive Pinion and Ring Gear 39-125


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39 Differential/Transaxle System 928Recommended Sequence for Adjustmentof Pinion/Ring Gear

If drive pinion and ring gear have to be adjusted, the following sequence of procedureswould be most economical.1. Determine total shim thickness Sges (S, plus S2) for specified preload of tapered roller

bearing/differential.2. Determine shim thickness Ss.3. Divide total shim thickness Sges into S, and Sz, so that specified backlash is between

ring gear and drive pinion.Objective of adjustments must be to regain the maximum degree of quiet running, as hadbeen determined by the special testing machine in manufacturing.Absolute cleanliness is essential for all assembly jobs and testing procedures to guaranteeperfect results.

After working on the final drive it will be necessary to adjust the pinion and ring gear,if parts had been replaced which have direct influence on said adjustment. The followingchart will help in avoiding unnecessary adjustments!

Ring Gear Drive Pinion Deviation r6, + Sz) 63)

Transm. case (automatic) or I x Xrear transmission caseBearing assembly for pinion X XFinal drive case X XSide transmission cover X XPinion/ring gear X XDifferential case XTapered roller bearing for differential X

-,1

039-126 Adjusting Drive Pinion and Ring Gear Printed in Germany


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928 Differential/Transaxle System 39ADJUSTING DRIVE PINION AND RING GEAR

General InformationAccurate adjustments of the pinion and ring gear are immensely important for the servicelife and smooth running of the final drive. This is why pinions and ring gears are pairedduring manufacture and checked in special machines for tooth pattern and quietness inboth directions of rotation. The position of smoothest running is determined by movingthe pinion in an axial direction, whereby the ring gear is lifted out of the no-play meshingposition far enough so that the backlash will be kept with specified tolerances. Deviation rfrom the adjusting distance called for by design (design distance R,) is measured andrecorded on face of drive pinion. Ring gears and pinions are designed so that deviation ris always added to R, i. e. is preceded by a + sign.

It l.

873 ate

2 3

R, = Design distance 74.70 mmr = Deviation from R in l/100 mm1 = Deviation r2 = Pair number3 = Backlash

Printed in Germany VIII, 1984 Adjusting Drive Pinion and Ring Gear 39-127


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39 Differential/Transaxle System 928Changes on Drive Pinion/Ring Gear

Since about January of 1984 manufacturing uses optionally drive pinions/ring gears, onwhich 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 nothave to be figured out for these drive pinions/ring gears.

-.

R, = Design distance 74.70 mmE = Adjusting distancer = Deviation1 = Adjusting distance (R, + r)2 = Pair number3 = Backlash

a39-128 Adjusting Drive Pinion and Ring Gear Printed in Germany


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928 DifferentiaI/Transaxle System 39Changes on Drive Pinions/Ring Gears

In the near future there will be drive pinions/ring gears with the following adjustinginformation.

R, = Design distance 74.70 mmE = Adjusting distancer = Deviation1 = Adjusting distance (R, + r), e. g. 75.05 m m2 = Pair number (three digits: 001 999)3 = Backlash

Note:The missing 5 mm thick gauge plate VW 385/17 must also be considered for adjustmentswith these drive pinions/ring gears.

Example:Recorded on ring gear - zdjustimj dZttiii& E = 75.05

Adjusting distance E 75.05 mmMissing gauge plate + 5.00 mmAdjustment of adjusting gauge 80.05 mm

Printed in Germany VIII, 1984 Adjusting Drive Pinion and Ring Gear 39- 129


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39 DifferentiaI/TransaxIe System 928ADJUSTING PINION

Pinion/Ring Gear Marked NOn these drive pinion/ring gear sets adjustingdistance E is calculated from known designdistance R, = 74.70 mm + deviation r,which is located on face of drive pinion.

1 = Deviation r in l/100 mm2 = Pair number

Note:The design of the drive pinion will not allowuse of the 5 mm thick Special Tool 385/l 7,normally applied for adjustments.Since Special Tool VW 385/30 includes this5 mm distance, it is important to add 5 mmto adjusting distance E.

Example:N 18 is the deviation r on face of pinion.R, = design distance 74.70 mmr = deviation + 0.18mmE = adjusting distance 74.88 mmMissing special tool + 5.00 mmAdjustment of master 79.88 mmgauge

Pinion;Ring Gear Marked D M On these drive pinion/ring gear sets DMis adjusting distance E

1 = Adjusting distance (75.00 mm inexample)2 = Pair number

Note:The design of the drive pinion will not allowuse of the 5 mm thick Special Tool 385/17,normally applied for adjustments.Since Special Tool VW 385/30 includes this5 mm distance, it is important to add 5 mmto adjusting distance E.

Example:DM 75 is adjusting distance on face ofpinion.DM = adjusting distanceMissing special toolAdjustment of mastergauge

75.00 mm+ 5.00 mm

80.00 mm

39 130 Adjusting Drive Pinion and Ring Gear Printed in Germany


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928 Differential/Transaxle System 391. Install bearing assembly with shims and

tighten collared nut to 380 Nm/275 ftlb.

2. Install final drive case (without shims)and tighten all bolts or nuts to 46 Nm/33 ftlb.

3. Install one side bearing cover withoutO-ring and secure with two bolts.

4. Adjust setring of Special Tool VW 385/lto distance a.

8. Install second side bearing cover withoutO-ring and secure with two bolts.

9. Pull out centering plate of master gaugewith the spindle that master gauge cans&II just be turned by hand.

10. Set Special Tool VW 385/30 to adjustingdistance E + 5 mm (for missing SpecialTool VW 385/l 7).

a=39mm5. Slide Special Tools VW 385/4 on to 385/l,

Install Special Tool VW 385/14 with dialgauge extension 9323.

R,= 74.70 mmr = + 0.18 mmE = 74.88 mm

+ 5.00 mm79.88 mm adjustment of

master gauge

6. Turn pinion that surface of collarednut is vertical.

7. Insert master gauge into case.

Example:

Printed in Germany VIII, 1984 Adjusting Drive Pinion and Ring Gear 39 131


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39 DifferentiallTransaxle System 928

a39.132 Adjusting Drive Pinion and Ring Gear Printed in Germany

Example:DM=E 75.00 mm

+ 5.00 mm80.00 mm adjustment ofmaster gauge

Il. Install master gauge and set (3 mmrange) dial gauge at zero with 1 mmpreload.

pr.w/ p-/ ,e I i

a;; h! g &, ;.;, i!~$$=-&~r L :-a*i. F

12. Turn master gauge carefully until dialgauge extension is vertical to face of drivepinion head. At this moment dial gaugeneedle will reach its point of reversedirection, at which dial gauge must beread.

Note:The measured value will always deviate fromthe set distance in clockwise direction(small needle of dial gauge will be between1 and 2). i. e. when adjusting the dial gaugewith 1 mm preload the value deviating from1 is added as shim thickness .&.

13. Install the determined shim thicknessS3 between transmission case and finaldrive case.

14. Recheck distance after installation ofshims with determined thickness.A deviation of ? 0.03 mm is permissible.


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928 Differential/Transaxle System 39ADJUSTING RING GEAR (Sges)

1. Clamp final drive case in a vise, using a 5. Check gap between transmission caseand side transmission cover with a feelergauge,

.

A = L-iron bar 6. Calculate shim thickness Sges.Sges. = gap - 0.30 mm (bearing preload)

2. Install differential with ring gear incase.

Example:3. Install side transmission cover (ring gear

end) without shims and tighten allhexagon head bolts to 23 Nm/17 ftlb.

4. Guide in second side transmission coverwithout shims carefully.

GapBearing preloadSges.

1.25 mm- 0.30 mm

0.95 mm

Printed in Germany - VIII, 1984 Adjusting Drive Pinion and Ring Gear 39 - 133


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39 Differential/Transaxle System 928ADJUSTING BACKLASH

1. Place shims determined for pinion adjust-ment between transmission case and finaldrive case. Install final drive case andtighten all mounting bolts to specifiedtorque of 46 Nm/33 ftlb.

2. Install differential in case.

3. Install side transmission cover, using totalshim thickness Sges as determined onring gear end and tighten all hexagonbolts to 23 Nm/17 ftlb.

4. Turn differential in both directions severaltimes, to settle tapered roller bearings.

5. Install measuring tools. Set Special ToolVW 388 to distance a = 80 mm.

6. Engage parking lock.

7. Turn rinq oear carefully by hand against_stop and set dial gauge to zero.

Hold drive pinion with locally made hookand turn back ring gear carefully. Readand note amount of backlash.

Hook made locally from flat iron 30 x 5 mm

39-134 Adjusting Drive Pinion and Ring Gear Printed in Germany


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928 Differential/Transaxle System 39DETERMINATION OF SHIMS S, AND Sz

Measured backlash must be brought to value Determining Shimspecified by manufacturer of pinion/ring Thickness S,gear by splitting total shim thickness Sges. (Opposite Ring Gear)

Backlash required is stamped on ring gear. S2 = Sges -S,Adjusted backlash value could be less by0.05 mm, but must never be greater than thestamped value. Example:

SgesS,

0.95 mm- 0.27 mm

0.68 mmDetermining ShimThickness S,(Ring Gear End)

Note:S1 = Sges (total shim thickness)

- measured backlash+ backlash inscribed on ring gear

Example:

Sges- measured backlash

+ inscribed backlash(by way of example)S,

0.95 mm0.88 mm0.07 mm0.20 mm0.27 mm

On the basis of experience with thesepinions/ring gears the shims S2 (oppositering gear) can be selected approx. 10 to 15 %thinner in favor of shims S, (ring gear end).

1. Remo

porsche 928 factory manual - volume 3

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