www.WorkshopManuals.co.uk
Technical Manual 9.1'.1' ~7~
(996)
Technical Information
Contents: Group 3
Transmission,manualtransmission
WKD483 721
911 Carrera
Transmission, manual transmission
Supplement Overview
Supple-
ment
Edition
05/1997
Article number
Topic Basic edition
Generalsupplement
11/2000
44
Generalsupplement
10/1999
35
Generalsupplement
06/1999
29
Generalsupplement
05/1999
28
Generalsupplement
04/1999
26
Generalsupplement
03/1999
25
Generalsupplement
02/1999
22
Generalsupplement
11/1998
18
Generalsupplement
08/1998
14
Generalsupplement
Generalsupplement
06/1998 07/1998
13
Generalsupplement
05/1998
9
Generalsupplement
12/1997
5
Generalsupplement
09/1997
4
OS/2000
0
12
Supplement
WKD483721
WKD483721.04 WKD483721.05 WKD483721.09 WKD483721.12 WKD483721.13
WKD483721.14 WKD483721.18
WKD483721.22 WKD483721.25 WKD483721.26 WKD483721.28 WKD483721.29 WKD483721.35
WKD483721.44
Overview
master3s
Printed in Germany -44,2001
www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk Foreword
911 Carrera (996)
Table of Contents
1
Foreword Foreword
Foreword Use..
Table of Contents Printed in Germany -44,
2001
masterVlt2
-1
page
-2
page
1 1
www.WorkshopManuals.co.uk 911 Carrera (996)
Foreword
Foreword This manualcontains Technicallnformation as well as instructions on repairsfor Porschevehicles. It is intendedfor the sole use of workshopsbelongingto PorscheAG. The descriptionsform the basis for professionaland correct maintenance and repair work. The content of the work procedures described is based on the level of training of a fitter who has completed vocationaltraining and has a sound knowledgeof the product. This level of knowledgeis necessaryin order to carry out the work described. Warning notes The warning notes and safety instructionsare classified by the respective signalisingword (Danger,Warning,Caution)besidethe warning symbol.
Warns against death or very serious injury which will certainly occur if the instructions
are not observed.
Warns against death or very serious injury which may occur if the instructions
are not observed.
Warns against minor injury or damage to property instructions
if the
are not observed.
To prevent injuryand restricted operating and traffic safety of the vehicle,or damageto the vehicle as the result of incorrect work, read these instructions carefullyand observe them withoutfail. It is not possiblefor PorscheAG to give a detailed evaluationof all danger situationsfor the personscarrying out the work. It is therefore imperativethat all personscarrying out repair and maintenance work on Porschevehiclesuse their specialistknowledgeto ensure that their own safety is not at risk and the procedure chosenwill not have any negativeeffects on the vehicle -especially with regard to
safety. It is therefore expresslyspecified that all work involvedin the work proceduresdescribed shouldbe carried out onlyin accordancewith the valid guidelinesand regulationsof the local authorities responsible with respect to health and accidentpreventionand environmen-
Foreword Printed in Germany -44,2001
-1 page 1 vorwort
www.WorkshopManuals.co.uk Foreword
tal protection, and in compliancewith the legal requirementsof individualcountries. Notes
Notes contain advisoryinformationrelated to the work procedure which makes the fitter's work easier. The following pictogram indicates this information:
rn Note! Containsadvisoryinformationwhich makes the work procedure easier. Due to the continuousdevelopmentand improvementof our vehicles, there may be discrepanciesbetweenthe actualtechnical status of the vehiclesand the work descriptions. Anyexisting deviationsare corrected by meansof supplements,and the scope of the descriptionsis extendedwith supplements. PorscheAG retains the right to implementchangesat anytime and without prior notice.
911 Carrera (996)
www.WorkshopManuals.co.uk 911 Carrera (996)
Foreword
Use The workshop documentationfor the 911 Carrera (996) model has the designation -"911 Carrera (996)" Technical Manual- and contains Technicallnformation as well as instructions on repairs. The integration of the technical informationpublishedin the "911 Carrera(996)" TechnicalManualwith the instructionson repairs provides the user with a complex referencework that combinesinto one book associated or cross-referencedmaterial of relevanceto workshopsand originatingfrom variousinformationmedia. The"911 Carrera (996)" TechnicalManualconsists of 15 folders, subdividedinto the following Groups .0
Entire vehicle-General
.0
Diagnosis,1 Engine,part 1 (up to RepairGroup 45)
.0
Diagnosis,1 Engine,part 2 (up to RepairGroup 69)
.1
Engine, part 1 (up to RepairGroup 13)
.1
Engine,part 2 (as of RepairGroup 15)
.2
Fuel,exhaust,engine electronics
.3
Transmission,manualtransmission
.3
Transmission,automatic transmission
.4
Runninggear
.5
Body
.6
Bodyequipment, exterior
.7
Bodyequipment, interior
.8
/ 9 Air conditioning/ Electrics
.9
Circuit diagrams, part 1 (up to and including'99 model)
.9
Circuit diagrams, part 2 (as of and including'00 model)
The two folders with Group a are to be regarded as one folder; i.e, file the "Technicallnformation"notices only in the folder "Groupa Diagnosis,part I" -up to Repair Group 45-. The second folder Group 0 Diagnosis,part 2 -as of Repair Group 69- includesthe further RepairGroupsbelongingto Group O. The two folders with Group 1 are to be regarded as one folder; i.e. file the "Technicallnformation"onlyin front of the repair descriptions in the folder Group 1 -Engine, part 1 -up to Repair Group 13-. The second folder Group 1 Diagnosis,part 2 -as of Repair Group 15- includesthe further RepairGroupsbelongingto Group O.
Use Printed in Germany -44,2001
-2 page 1 handhabung
>
www.WorkshopManuals.co.uk Foreword
The two folders with Group 9 are to be regarded as one folder; i.e. file the liTechnicallnformation"notices only in the folder Group9 Circuit diagrams, part 1 -up to '99 model-. The second folder Group 9 Circuit diagrams, part 2 -as of '00 model- includesthe further RepairGroupsbelongingto Group 9, The "Boxster (986)"TechnicalManualhasthe same structure in each folder, with the following breakdownfor all Groups:
Title page: "Boxster
(986)" Technical
Manual
> Foreword
Title page: "Technical information" Table of contents,Technicalinformation>Technicalinformation Title page: "Repair"
> RepairGroups:overview> Table of contents,repairs> General technical data> Instructionson repairs As can be seen from the breakdown,the publishedTechnicallnfor. mation is in the front part of each folder -numbered according to the Groups.The Table of Contentsassignedto each Group will be periodicallyupdated. Followingthe Technical Information,separated by a title page, the instructionson repairs -assigned according to the Groupsor broken down into RepairGroups-are includedin the folders. The instructions on repairswill be extendedand updated by means of supplements.
rn Note! Sheets that alreadyexist in the "911 Carrera (996)" TechnicalManual and are updated or revised and therebyexchangedby a supplement are designatedin the footer with the supplementnumber correspondingto the current version:e.g. "Printed in Germany-2,-
2000"
rn Note! Due to a system modificationin the TechnicalLiterature production, the following procedures have changedin model year 2000!
9.11 Carrera (996)
www.WorkshopManuals.co.uk Foreword
911 Carrera (996)
1 -The previous record sheet in the folder "O-Genera!" and the supplement omitted.
contents
A supplement
sheet -red sheet- have been
overview now appears sepa-
rately in each folder. The new supplement sheet can be destroyed
contents
after the supplement
is filed in
the folder.
rn Note! The supplementoverviewsheet is replaced with the relevant supplementin the correspondingfolder and must no longer be maintainedby hand. 2 -The
page numbering
in the new and the replaced chap-
ters are no longer continuous. given an additional
Each new chapter is now
chapter number followed
by the
page number e.g.-2 Page 11 => Rep. Gr. 0; General 3 -The old page numbering
still applies to existing chap-
ters and those that are not replaced.
Use Printed in Germany-44. 2001
-2 page 3 handhabung
www.WorkshopManuals.co.uk 911 Carrera
(996)
Group 0:
Group 0:
Overview of repair groups
0
Entire vehicle -General Salescheck Maintenance
01
03
0 03
Diagnosis On-boarddiagnosis DMEdiagnosis Tiptronicdiagnosis ABSdiagnosis
Group 0:
Group 1:
24
37
45
Diagnosis
0
Convertible-topdiagnosis Airbag diagnosis Roll-overprotection system diagnosis Seat memory diagnosis Heating diagnosis Alarm system diagnosis PCMdiagnosis ParkAssistentdiagnosis HBAdiagnosis
61 69 69 72
Group 2:
Group 3:
Group 3:
13
Engine-Cylinder head,valve drive Engine-Lubrication Engine-Cooling
15 17 19
Fuel, exhaust, engine electronics Fuelsupply,control Exhaustsystem,turbocharging Fuelsystem,electronicinjection Fuelsystem,K-Jetronic Exhaustsystem Starter,powersupply,cruisecontrol Ignitionsystem
2 20 21 24 25 26 27 28
Transmission,
3
manual transmission
Clutch,control Manualtransmission-Actuation, housing Manualtransmission-Gears, shafts, intogearsh. Final drive, differential,differential lock
30 34 35 39
Transmission, automatic Torqueconverter
3
transmission
Overview of repair groups in Germany -35,
10
1
Engine
Automatic transmission-Actuation, housing Automatic transmission-Gears, control Final drive, differential,differentiallock
Printed
90 91 91 94
1
Engine Engine-Crankcase, suspension Engine-Crankshaft, pistons
Group 1:
80
October
1999
REPGRU.CHP
32 37 38
39
www.WorkshopManuals.co.uk Overview of repair groups
Group 4:
Group 5:
Group 6:
Group 7:
Group 8:
911 Carrera (996)
Running gear
4
Front wheel suspension,drive shafts Rear wheel suspension,drive shafts Wheels,tires, suspensionalignment Ant~LockBrake System (ABS) Brakes -Brake mechanics Brakes -Hydraulics, regulator, booster Steering
40 42 44 45
46
47 48
Body
5
Body front Body center, roof, frame Body rear Lids, flaps Door front, central locking system
50 51 53 55 57
6
Body equipment, exterior Slidingroof Convertible top, hardtop Bumpers Glazing,windowcontrol Exteriorequipment Interiorequipment Passengerprotection
60
61 63 64
66 68
69 7
Body equipment, interior Linings,insulation Seatframes Seatupholsteries, covers Air
70 72 74
8
conditioning
80
Heating Ventilation Air conditioning Auxiliary air conditioning system
Group 9
85 87
88 9 90
Electrics Instruments,alarm system Radio,telephone,on-boardcomputer, navigation Windshieldwiper and washer system Lights, lamps, switches exterior Lights, lamps, switches interior, theft protection
Group 9: Group 9:
91 92 94
96
Circuit diagrams
9
Wiring (up to and includingthe '99 model)
97
Circuit diagrams
9
Wiring (from the '00 model)
97
Overview of repair groups REPGRU.CHP
Printed
in Germany
-35,
October
1999
www.WorkshopManuals.co.uk Transmission, manualtransmission
911 Carrera
Table of Contents
3
Transmission, manual transmission
3
Transmission Technical data
,
6-speed manual transmission G96/30 -Manual
...,
transmission tightening torques
FrontwheeldriveZ96.00 -Front-axle
30 305019 305037 300107 303019 300519 30 304519 34 340155 343519 340819 341219 344919
Clutch,
Clutch Disassembling Bleeding Removing
,
drive tightening torques.
...,
3-1
page
3-1
page
1 1
3-1
page
3
3-1
page
4
3-1
page
4
control
boost
the
Removing
and
clutch springs:installing and
and
installing
assembling system Allocationthe clutch
clutch
release
slave clutch. and
pedal
bearing
Manual transmission
-Actuation,
Changing Removing
oiltransmission closure shift
transmission and
installing
cylinder.. grease
30-1 30-3 30-5 30-7 30-9 30-17 30-21
specification.
-GT3
ass. housing
console cap selector for G and
96 selector cables.
force
35
Manual
355019
Removing andinstallingsealingringfor inputshaft.
39
Final drive -Differential,
392019 392219
Removingand installingcover for final drive
transmission
-Gears,
shafts,
differential
34-1 34-3 34-7 34-11 34-19
mechanism.
into gearsh.
35-1
lock
,
39-1
Removingand installingsealingring for halfshaftflange of limited-slip ,
39-3
Removingand installingsealingring for halfshaftflange of differential
39-7
differential.
Table of Contents Printed in Germany -44, 2001
master3s
www.WorkshopManuals.co.uk Transmission
911 Carrera
Technical data 6-speed manual transmission G96/30
lype
Code letter
G96/30
Technical
Equipment
Installed in
Model year
6-speed
911 Carrera 4 (996)
1999
3-1 page1
data
Printed in Germany-44,2001
c3xxxxxl
www.WorkshopManuals.co.uk 3 Structure
Transmission
of the transmission
Manual transmission
number
911 Carrera
3081
www.WorkshopManuals.co.uk Transmission
911 Carrera
3
Manual transmission tightening torques
Screw Drive
plug, shaft
Clutch Guide
oil drainage
on the transmission
slave tube
and oil filling
cylinder
M22
flange
M1 0
on transmission
for release
bearing
for release
lever
M8
23 24
M8
25
M8
25
M 12 / M 1 0
85 / 45
M8
on trans-
miSSion Ball journal
on tranmis-
sion Cover
for final
drive
on transmission
hous-
ing Transmission
on engine
Reversing
light switch
on transmission
M12
15
Holder
shift cables
on transmission
M1 0
45
M20
120a)
Cardan Drive
for
flange shaft
on transmission
on transmission
flange
M1 0
45
a) Counter collar nut with 170 Nm (126 ftlb), loosen again and tighten to 120 Nm (89 Nm) ='>Rep. Gr. 3982 19; Install and remove sealing ring for cardan flange.
3-1 page 3
Technical data Printed in Germany -44.2001
c3xxxxxl
www.WorkshopManuals.co.uk 3
911 Carrera
Transmission
Front wheel drive Z 96.00
General data
I Transmissionratio, final drive (Z2 : ZI = i)
Front-axle final drive Z 96.00
31 : 9 = 3,44
Finaldrive
Bevelgear drive withouthypoid offset
Fillingcapacity
approx.l.51
Front-axle drive tightening torques
Screwplug, oil drainage and oil filling
28
Cover on final drive
25
Long-necktube on final drive
25
Drive shaft on final drive
39
Reartransmission support to transmissionmount
65 65
Reartransmission support on body
www.WorkshopManuals.co.uk 911 Carrera
Transmission
65
Fronttransmission support on front-axlecross member Studs on front-axlecross member
M8
20
Frontcross member to final drive
MIa
65
Drive shafts on front-axlefinal drive
M8
39
Diagonalbraces on body and front-axlecross member
MI2
100
M8 x 40
23
M6
7
Tankstrap on body Pipe holder on transmission support
3-1 page5
Technical data Printedin Germany-44,2001
c3xxxxxl
www.WorkshopManuals.co.uk 911 Carrera (996)
3
Transmission
Technical data (manual transmission G96/00J
Key to transmission numbers
127_97
G9600
1
001014
T
T Transmission type
Index for version within transmission number
Serial number
1 = normal differential 2 = limited-slipdifferential
3
Technical data (manual transmission G96jOO)
Printed in Germany
-18,
1998
9963_1
3-3
.
www.WorkshopManuals.co.uk 911 Carrera (996)
Transmission
Technical data (manual transmission G96/00J Manual transmission G96jOO
3
Technical data (manual transmission G96jOO)
Printed in Germany
-18,
1998
9963_1
3-5
www.WorkshopManuals.co.uk 911 Carrera (996)
Transmission
Technical data (manual transmission G96/00J Tightening torques (transmission G96jOO) Location
Thread
Tightening torque Nm (ftlb.)
Screw plug, oil drainage and oil filling
M22
30 (22)
flange
MID
81 (60)
Clutch slave cylinder on transmission
M8
23 (17)
Guidetube for release bearing on transmission
M8
24 (18)
Ball journal for release lever on transmission
M8
25 (19)
Coverfor final drive on transmission
M8
25 (19)
Halfshaftflangeon limitedslip differential
MID
44 (33)
MI2
85 (63)
MID
45 (33)
Reversinglight switch on transmission
M12
15 (11)
Bracket for shift cables on transmission
MID
45 (33)
Drive shaft on transmission
Transmission on engine
3
Technical data (manual transmission G96jOO)
Printed in Germany
-18,
1998
9963_1
3-7
www.WorkshopManuals.co.uk 911 Carrera (996)
30 50 19
Clutch, actuation
Removing and installing clutch
Tools
165_98
Item
Designation
Special tool
A
Centringmandrel
9102
B
Toothedsegment
9538/1
B1
Fastening screw for toothed segment
30 50 19
Hexagon-head bolt M12 x 50
30-1
Removing and installing clutch
Printed in Germany
-13,
1998
Explanation
996301
~ 3.
www.WorkshopManuals.co.uk Clutch, actuation
911 Carrera (996)
Assembly instructions Removal
Installation
1. Removemanualtransmission.Referto Group3 -Manual transmission, ServoNo. 3435 19.
1. Fit centring mandrel (special tool 9102) with drive plate in the guide bearing (needle bush),
2. Fastentoothed segment (special tool 9538/1) on the crankcase half (cylinder bank 1 -3) with hexagon-headbolt M12 x 50.
2. Fit thrust plate. Alwaystighten pan-headscrews in several stages and in diametricallyopposite sequence. Tighteningtorque: 23 Nm (17 ftlb.) 3. Removecentring mandrel.
\' .-",
\-,
n 607_97
Detach thrust plate. Note In order to avoid deformation of the thrust plate housing, always loosen screws in several stages and in diametrically opposite sequence.
4. Removethrust plate and drive plate.
30 50 19
30 -2 996301
Removing and installing
clutch
Printed in Germany -13, 1998
~ 11
www.WorkshopManuals.co.uk 911 Carrera (996)
30 50 37
Clutch, actuation
Disassembling and assembling clutch
8
I 6
I
r .
~
-J
L1
I
.~
~
I
I
3
4
5 414_96
30 50 37 Printed
Disassembling and assembling clutch
in Germany
-13,
1998
996301
30 -3
www.WorkshopManuals.co.uk
Disassemblingand assembling clutch Note: No.
Desi nation
.Removal
1
Releaselever
1
2
Releasebearing
1
Installation
Do not wash out bearing. Replace noisybearing. Do not grease sliding surface of release bearing or guide tube
3
Retainerspring
1
4
Pan-headscrew M8 x 16
6
5
Thrust plate
1
6
Drive plate
1
Grease ball journal at the contact point with the retaining spring using Optimol Longtime 3EP The bolts must alwaysbe loosenedin several steps and crosswise in order to preventdeformation of the thrust-platehousing
The bolts must alwaysbe tightened in several steps and crosswise in order to prevent deformation of the thrust-platehousing
Centre with centring mandrel,special tool 9102
7
Pan-head screw
8
Initial torque 25 Nm
MIO x 1 x 50 8
Double-massflywheel
9
Needle bush
30 -4
(19 ftlb.) Final torque: 900 turn
1
Ensurethe centring pins are seated firmly
30 50 37 996301
Disassembling
and assembling
clutch
Printed in Gennany -13, 1998
www.WorkshopManuals.co.uk 911 Carrera (996)
30 30 19
Clutch, actuation
Removing and installing clutch slave cylinder
Removal 1. Unscrewthe front rear-axle cross member (two MID screws) to facilitate subsequent assemblywork.
/
2. Detach line No.1 on the clutch slave cylinder and remove line from holder No.2. Cover or close line No.1 and the connectionbore in the clutch slave cylinder. 3. Removeholder with clip No.2 (to facilitate assembly). To do this, undo the 2 screws on the transmission side cover.
314_98
Installation 4. Undo fastening screws No.3 and remove the clutch slavecylinderfrom the transmission
1. Greaseend of the push rod of the clutch slave cylinder -in the area located in the ball socket of the release lever when installed-
housing.
with a thin coat of Olista Longtime 3 EP (availableas a spare part).
Note The following tools can be used to undo and tighten screws No.3:
2. Fit the clutch slave cylinder and tighten the fastening screws (23 Nm (17 ftlb.)).
Lower screw: 3/8 inch changeover ratchet in combination with a short extension (approx. 100 mm long)and 13 mm socket wrench insert.
Note
Wheninserting clutch slave cylinderI it is necessaryto overcome the spring force acting on the push rod whilst fitting a fastening screw. Refer to the assembly instructionsin the following text.
Upper screw: 3/8 inch changeover ratchet in combination with an extension (approx. 250 mm long), universaljoint and 13 mm socket wrench insert.
3030
19
Removing and installing clutch slave cylinder
Printed in Germany -13, 1998
996307
30 -7
www.WorkshopManuals.co.uk Clutch, actuation
Assembly instructions for inserting the clutch slave cylinder
3. Fit clutch line on clutch slave cylinder (do not tighten it yet). Fit holder with clip on the transmissionside cover (tighteningtorque of the two screws: 25 Nm (19 ftlb.)). Clip clutch line into the holder and tighten the line.
Move clutch slave cylinder to installation position and then fix/centre it at the lower fastening point using a drift punch (A) measuring 5 x 120 x 10 mm. Align clutch slave cylinder -with punch (A) in place -so
911 Carrera (996)
4. Bleed hydraulic system of the clutch (Rep.Gr. 30/ ServoNo. 30 01 07).
the drift
that the upper
fastening screw No.3 can be fitted.
Important notes: After fitting the upper fastening screw No.3, remove the drift punch (A)and screw in the lower fastening screw.
The clutch hydraulics must always be filled or bled using a pressure filling and bleeding device. Furthermore,the bleeder valve must be opened sufficientlyand the gauge pressure must be approx. 1.5 bar.
Tighten upper and lower fastening screws (23 Nm (17 ftlb.)).
Before the system is filled or bled, the clutch pedal must be in the "Pedal fully depressed" position.
Important: As there is no system pressure, servo kinematic effects will cause the clutch pedal to move forward abruptly. In order to avoid damage,the pedal must be guided manually. Bleed the system until no more bubblesappear at the bleeder valve (use a collecting bottle with transparenthose). 350_98
If the system was open previously I the minimum filling or bleeding time must be 30 seconds.
5. Check operation of the clutch. Repeatthe bleeding process if the clutch does not operate (disengage)correctly. 6. Install rear axle cross member. Tighteningtorque of the two screws 65 Nm (48 ftlb.).
30-8
30 30 19 996307
Removing and installing
clutch slave cylinder
Printed in Germany -13, 1998
www.WorkshopManuals.co.uk 911 Carrera (996)
30 05 19 Important
Clutch, actuation
Removingand installing the clutch pedal
notes
The description below appliesto left-handdrive vehicles. On right-handdrive vehicles,the clutch pedal lever is located directly next to the brake pedal (separated by the steering outer tube in the case of left-handdrive vehicles). Assembly/disassemblyfor right-handdrive vehicles is similar to the procedure for left-handdrive vehicles. Before the start of disassemblywork on the pedals,the clutch boost spring must be fixed with a cotter pin (arrow at No.5). Important: secure the cotter pin (bend it over).
465_98
3005 Printed
19
Removing and installing the clutch pedal
in Germany
-18,
1998
996309
30-9
. .-.
www.WorkshopManuals.co.uk 911 Carrera (996)
Clutch, actuation
Removing and installing the clutch pedal
@
@
:::",
6x
~\ ".
...'
I
5a /
i";
~
rl~i
)"
..~
{Q1),~~
'--,
2
~ :
~
5!
6
/
~
1
;
'\::;J
465_98
A = Clutch pedal area B = Brake pedal area
30 -10
3005
19
996309
Removing and installing the clutch pedal Printed
in Germany
-18,
1998
www.WorkshopManuals.co.uk 911 Carrera (996)
Clutch, actuation
A = Clutch pedal area
Note:
No. Designation
Qty.
1
Switch
1
2
Retainingclip
1
3
Pin
1
4
Clamp
1
5
Boost spring with bracket
1
Removal
Installation
Releaseby turning 90°, and pull out of the installation opening
Before installation,pull operating plunger out of the switch as far as it will go Replaceif necessary
Replace Secure boost spring with cotter pin (arrow at No.5) Insertthe cotter pin (/33 mm) into the assemblybore and bend over ends. Then undo the three fastening nuts of the bracket (arrows)and remove the boost spring together with bracket and clutch pedal lever (No.6)
Installthe assembly consisting of bracket, boost spring and clutch pedal lever. Ensure correct allocation when replacingthe boost spring. * * Observe assemblyand adjustmentspecification for the bracket (assembly instructionsunder Installation,step 3)
5a
Boost spring bearing
2
Replaceif necessary. It is importantto note instructionsregarding grease**
5b
Pin
1
It is importantto note instructions regarding grease**
6
Clutch pedal lever
1
Removetogether with boost spring No.5 and
bracket 6X
2
Bushings
Remainin the clutch pedal lever
Check,replaceif necessary.
Lubricate. Use specified grease* Lubricate the bushings of the clutch and brake pedals (6X and 14X) with "Optimal, Optitemp LG 2" grease, Part No.: 000.043.203.37 (deliveryquantity: 80 g tube). * * Informationcan be found in RepairGroup 30 -Servo No. 30 Clutch boost spring: allocationand grease specification. To see when lubrication of the boost spring bearing points is not permitted, please also refer to the assemblyinstructionsfor installation,steps 2.1 and 2.2.
30 05 19
Removing and installing the clutch pedal
Printed in Germany
-18,
1998
996309
30 -11
www.WorkshopManuals.co.uk Clutch, actuation
911 Carrera (996)
Notes on removal and installation Removal
&
4. Detachdiagnosticsocket.
Warning Danger of injury and / or damage during disassembly and assembly work! The clutch boost spring can become detached on its own. > Before the start of disassembly work in the area of the clutch pedal lever (exception:clutch pedal switch),the clutch boost spring must be fixed with a cotter pin (Figure478_98) .
1. Disconnectbatterygroundcable. 2. Removedriver'sseat(to facilitatework), 5. Detachrelaycarrier,unclipandlowerinto the footwell.
3. Removeair duct (A). The air duct is plugged in.
86_98
6. Releaseclutch pedal switch by turning it.9Oo and pull it out of the installationopening. 290_1_97
30 -12
30 05 19 996309
Removing and installing the clutch pedal Printed in Gennany -18, 1998
www.WorkshopManuals.co.uk 911 Carrera (996)
Clutch, actuation
7. There is an assemblybore in the guide rod for the clutch boost spring. Insert a 3 mm 0' cotter pin in this bore, and bend over the ends (securing: refer to Figure478_98).
10. Undo fastening nuts from boost spring bracket (arrows). Requirement: Boost spring secured with a cotter pin. Removeclutch pedal lever together with boost spring and bracket.
8. Removepin between the clutch push rod and clutch pedal lever. 9. Removeretainer (1) on the pedal bearing axle.
n 8
x
< 478_98
Installation 1. Inspectall bearing bushings X for clutch pedal lever and replace them if necessary. Lubricate sliding surfaces of the bearing bushingsX (Figure466_98) and the pedal bearing axle with Optimol,Optitemp LG 2, Part No. 000.043.203.37.
A -Clutch pedal lever B -Brake pedal C -Steering outer tube X -Bearing bushings
466_98
-Retainer
2. Assemble boost spring, bracket and clutch pedal lever. Descriptionunder step 2.1 or 2.2. 2.1 Carrera (996) Mod. '98/ some Mod. '99 2.2 Carrera (996) from current Mod. '99 Note In the 911 Carrera(996), different boost springs may be fitted. Observeproper allocationwhen replacing the boost spring and/or the bracket.
30 05 19 Printed
Removing and installing the clutch pedal
in Germany
-18,
1998
996309
30 -13
www.WorkshopManuals.co.uk Clutch, actuation
911 Carrera (996)
A modified (optimised)clutch pedal must also be sometimes be using when replacing the boost
2.2 Carrera(996)from currentMod.'99
spring.
Identification/differentiation: Push rod closed / boost spring parts coated. The date of introductionfor this boost spring is containedin the Parts Catalogue.
Greasing of the boost spring bearing points is partly necessary and partly not permitted (dependinguponthe type of boost spring used).
Engagethe hexagon bolt of the boost spring in the hexagonon the clutch pedal (arrow).
Informationcan be found in the Technical Manual-Repair Group 3D, ServoNo. 30 Clutch boost spring: allocation and grease specification,
Important: Do not grease, as the sliding surfaces of this type of boost spring are coated. This non-greasinginstructionappliesto all sliding surfaces (pin of boost spring, boost spring bearing in bracket, bearing pin on boost spring and boost spring in the shell).
2.1 Carrera (996) Mod. '98/ some Mod. '99 Identification/differentiation: Push rod of boost spring open on one side, boost spring parts not coated.
Grease pin for boost spring (arrow) with mating bearing on the boost spring push rod, the boost spring bearing (arrows) and the bearing pins on the boost spring with Optimol, Optitemp LG 2, part No. 000.043.203.37. First remove old grease with solvent naphtha.
u
\~
Do not grease (not permitted)
467_98
Note
Greasing necessary (arrows)
30 -14
31_1_98
Gold-colouredbracket (996.423.571.00) and boost spring with purple marking (996.423.081.09 Mod. '98/ some Mod. '99 or 996.423.081.11 from current Mod. '99) must be used only in this combinationand installed only in the 911 Carrera(996).
30 05 19 996309
Removing and installing the clutch pedal Printed in Germany -18, 1998
www.WorkshopManuals.co.uk Clutch, actuation
911 Carrera (996)
3. Installationand adjustmentspecificationfor boost spring bracket. Install preassembled boost spring bracket with clutch pedal lever.
~""~ ~
To do this:
-~-;::?'
",
Step1:
~
Tighten the three fastening nuts (arrows) only
4.
1.+5.
slightly (the bracket must still be movable).
2.
Step2: Tighten the clutch master cylinder to 10 Nm (7.5 ftlb.) (if the clutch master cylinder was detached).
\I~
~
JII
32_98
Step3: Press the clutch pedal againstthe direction of travel until the pull stop in the clutch master cylinder is reached.
Note
The push rod of the clutch save cylinder should not be lubricated in general (for all versions).
Step4: Removecotter pin (retaining pin) on the spring cup so that the clutch pedal is pressed against the rubber stop in the boost spring bracket.
4. Fit new retainer on the pedal bearing axle and subsequentlysecure the retainer by wedging it with a mandrel.
Step5:
5. Install clutch pedal switch. First pull operating plunger out of the switch as far as it will go. By means of its self-adjustmentfunction, the switch then compensatesfor tolerances in the pedals.
The bracket is screwed down with the clutch pedal pressed back (to make full use of the slots). Tighten hexagon nuts (arrows)in the prescribed sequence. Tighteningtorque: 7.5 Nm (5.5 ftlb.).
Sequence:5a / 5b / 5c
30 05 19 Printed
Removing and installing the clutch pedal
in Germany
-18,
1998
996309
30 -15
www.WorkshopManuals.co.uk Clutch, actuation
911 Carrera (996)
6. Checkthe interlockswitchadjustment on vehicleswith interlock. Adjustment
specification
for interlock
switch:
The switch must be aligned so that, with the clutch pedal depressed, it is operated approx. 1 to max. 2 mm before the limit stop of the clutch slave cylinder is reached.
49_98
7. Installrelaycarrier,diagnosticsocketand air duct. 8. Perform a function test on clutch and brake operation.
30 -16
30 05 19 996309
Removing and installing the clutch pedal Printed in Germany
-18,
1998
www.WorkshopManuals.co.uk Clutch, actuation
911 Carrera (996)
30
Clutch boost spring: allocation and grease specification
1. Boost spring / bracket allocation
2. Standard boost spring allocation
Gold-colouredbracket (996.423.571.00) and boostspring with purple marking(996.423.081.09 or 996.423.081.11 / see boost spring allocation) must be used only in this combinationand installed only in the 911 Carrera (996).
2.1 Carrera
Mod. '98/
some Mod. '99
Boost spring A. Push rod of boost spring open on one side. Boost spring with purple marking.
Observe replacementprocedure and grease specification.
Note The silver~olouredbracket(986.423.571.00) and boostspring withwhite marking(986.423.081.08 or 986.423.081.11) are assignedto the Boxsterand must not be installedin the 911 Carrera(996).
2.2 Carrera as of current Mod. '99 Boost spring B. Push rod of boost spring closed. Boost spring with purple marking. Do not grease any areas as the components are coated.
31_98
* Differentiation/identification 556_98
30
Clutch boost spring: allocation and grease specification
Printed in Germany
-18,
1998
9963017
30 -17
-.
www.WorkshopManuals.co.uk Clutch, actuation
3. Boost spring: Replacementprocedure 3.1 Carrera
911 Carrera (996)
WhenboostspringB is installedfor the first time,the optimisedclutchpedal 996.423.139.09mustalsobe used.
Mod. '98 / some Mod. '99
The standard boost spring A (push rod on boost spring is open on one side / boost spring painted purple) Spare Part No. 996.423.081.09 is no longer available after existing supplies are used up.
Boost spring B 996.423.081.11 can then be used as a replacement(closed push rod / boost spring painted purple). This boost spring must not be greased.
'. ~ .~. ~..~_.'. /
~
467_98
n
Note
A
Hexagonbolt 999.423.315.06 and retainer 999.166.022.02 are includedwith the boost spring to enable it to be attached to the optimised clutch pedal.
B
This scope of deliveryis the same as for boost spring type B (as of current Mod. '99). 556_98
3.2 Carrera
as of current Mod. '99
Boost spring B (Figure556_98) is used as standard and for replacement.
30 -18
30
Clutch boost spring: allocation and grease specification 9963017
Printed
in Germany
-18,
1998
www.WorkshopManuals.co.uk 911 Carrera (996)
Clutch, actuation
4.2 Clutch master cylinder push rod
4. Grease specification
Do not grease, as this could result in damage. The following grease specification must be observed during assemblywork on the pedals.
4.3 Area around boost spring Dependingupon the type of boost spring used, greasing is either necessaryor not permitted. The followinggeneralrule applies:Do not grease coated parts, as otherwise the coating is lost.
4.1 Pedal bearing axle Greasinggenerallynecessary. Lubricate sliding surfaces of the bearing bushings X and the pedal bearing axle with Optimal, Optitemp LG 2, Part No. 000.043.203.37.
4.3.1 Carrera Mod. '98/
some Mod. '99
A. Boost springs installed as standard: Push rod open on one side. Parts uncoated. Grease pin for boost spring (arrow)with mating bearing on the boost spring push rod, the boost spring bearing (arrows)and the bearing pins on the boost spring with Optimal,Optitemp LG 2, Part No. 000.043.203.37. First remove old grease with solventnaphtha. The boost spring and interior of the boost spring housingare lubricated with a special grease. This grease is not availableas a spare part. If necessary,replace the complete boost spring (with housing).
A -Clutch pedal lever B -Brake pedal C -Steering outer tube X -Bearing bushings
466_98
~
1 -Retainer 31_1_98
30
Clutch boost spring: allocation and grease specification
Printed in Germany.
18, 1998
9963017
30 -19
www.WorkshopManuals.co.uk Clutch, actuation
B. Spare part replacement
911 Carrera (996)
boost springs
Part No. 996.423.081.11 (type used as of current Model '99/ Figure467_98). Distinguishingfeature: closed push rod, boost spring with purple marking and
hexagon bolt for attachmentto the clutch pedal.
Do not grease anyareasas the components are coated.
4.3.2 Carrera
as of current
Mod. '99
Push rod closed / attachmentto clutch pedal by means of a hexagonbolt. Do not grease any points, as the parts are coated.
~
467_98
30 -20
30
Clutch boost spring: allol:ation and grease specification 9963017
Printed in Germany.
18, 1998
www.WorkshopManuals.co.uk 911 Carrera (996)
30 45 19
Clutch, control
Removing and installing release bearing -GT3
5
3
354_99
30 45 19 Printed
Removing
in Germany
-28,
and installing
1999
release bearing 9963021
-GT3
30 -21
www.WorkshopManuals.co.uk Clutch, control
911 Carrera
(9961
Removing and installing release bearing -GT3 No. Designation Snap ring
Note: Removal
Qty. 1
Installation
Removeusing pointed-nose
Ensure correct seating
pliers, simultaneouslypush down pressure plate using a press
2
Thrust plate
1
Engage lug (twist lock) in the opening of a diaphragm spring latch
3
Releasebearing
1
Check,do not wash out,
Do not grease sliding
just dry wipe
surface
4
Spring washer
1
5
Spacer washer
2
Fit 2 spacer washers
6
Pressure plate
1
Check for wear, replace if necessary
30 -22
Mountin correct position
30 45 19
Removing and installing
9963021
release bearing
Printed
in Germany
-28,
-GT3 1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Clutch, control
Removing and installing release bearing -GT3 Assembly instructions
1. The snap ring can be fitted only using a workshop press. Use a block of hardwood as a pressure piece.
3. Do not grease the sliding surfaces of the release bearing and the guide tube. The guide sleeve is slotted (irregular course -arrow)
II
~./
355_99 358_99
2. Fitspringwasherin correctposition.
356_99
30 45 19 Printed
Removing
in Germany
-28,
and installing
1999
release bearing 9963021
-GT3
30 -23
www.WorkshopManuals.co.uk 911 Carrera {996}
34 49 19
Manual transmission actuation, housing
Removing and installing closure cap for ~ielector mechanism
Tools
500_98
Item
Designation
Special tool
Mandrel
P 375
34 49 19 Printed
Explanation
Removing and installing closure cap for selector mechanism
in Germany
-18,
1998
9963419
34 -19
.. ~ ~
www.WorkshopManuals.co.uk Manual transmission actuation, housing
911 Carrera (996)
Removing and installing closure cap for selector mechanisnrl
~~~~~~11E c
~ 111"
"" "
\
\
I
)
'\
'"" \
.
~-:
,..;~(
I
/
/'
!
,I
\.
~
" ~
,
)
075_98
A- Closurecap
34 -20
34 49 19
Removing and installing closure cap for selector mechanism 9963419
Printed
in Germany
-18,
1998
www.WorkshopManuals.co.uk 911 Carrera (996)
Manual transmission actuation, housing
Removing and installing closure cap for selector mechanism Removal
1. Removetransmission (refer to Service No. 34 35 19). 2. Shift gear lever to neutral, unscrewfastening screw "A"and remove snap ring "B".
484_98
Installation
1. Insertthe closurecap andsnapring into the holein the housing. A -Fastening screw B -Snap ring C -Closure cap
076_98
2. Using special tool P375 press the snap ring and closure cap down until the snap ring engagesinto its groove.
3. Drill a hole of 3.5 mm in the centre of the closure cap (coat drill with thick grease in order to prevent drilling chips from falling into the transmission),screw in sheetmetal screw (4.8 x 25) with a large washer and lever out the closure cap using two screwdrivers.
Note Ensure that the snap ring is perfectly secure,
3. Tightenthe fasteningscrewfor the wheel bearinghousingto 25 Nm (19 ftlb.). 4. Installthe transmission.
3449 Printed
19
Removing
in Germany
-18,
and installing
1998
closure cap for selector mechanism 9963419
34 -21
www.WorkshopManuals.co.uk 911 Carrera (996)
34 01 55
Manual transmission
-Actuation,
housing
Changing transmission oil
Filling capacity: 2.7 I Note
Use only oils approved by Porsche. See Parts Catalogue. 1. Unscrewthe oil filler and drain screws and drain the oil with the vehicle horizontal.
',( ~\
~.)11
~.\.
/
Ji 1 -Filler screw 2 -Drain screw
88- 97
2. Cleanthe drain and filler screws. 3. Fill with oil up to the bottom edge of the oil filler opening.
4. Tightenthe drainandfiller screwswith 30 Nm (18 ftlb.).
34 01 55
34 -1
Changing transmission oil
Printed in Germany, 1997
996341
www.WorkshopManuals.co.uk 911 Carrera (996)
34 35 19
Manual transmission
-Actuation,
housing
Removing and installing transmission G 96
Tools
138-97
Item
3435
Designation
Special tool
Retainingdevice
9624/1
19
Removing
Printed in Germany, 1997
and installing
transmission
Explanation
G 96
996341
34 -3
www.WorkshopManuals.co.uk
Removingand installing transmission Removal 1. Removeunderbodypanels(middleandrear).
7. Unscrewthe clutch slave cylinder and hang up at the side with the hose connected.
2. Removethe cross member which passes under the transmission.
Note The clutch pedal must not be pressed if the slave cylinder has been removed. Danger of injury from flying piston rod. Affix a warning note in the vehicle!
3. Secure the engine in installationposition with special tool 9624/1. To do this, remove the mountingfor the stabilizer, swivel the stabilizer forward and screw on special tool 9624/1 with four fastening screws. Screw in the pressure screw until the pressure disc has contact with the crankcase,
8. Disengageshift and selector cables on the transmission:
(o/f
IJ'
"-'"
-;;/-:::; ~
-
..,,~ 133-97
132-97
Note 4. Removedrive shafts at the transmissionand protect the shafts against damage (use scrap pieces of hose with a diameter of 30 mm).
The shift and selector cables must not be excessivelybent or kinked. Pull off shift and selector cables at the transmission shift and selector levers.
5. Disconnectthe plug connectionfor the reversing light switch. 6. Unclipthe hydraulic line for the clutch slave cylinder at the side transmission case cover.
34 -4
34 35 19 996341
Removing and installing
transmission
G 96
Printed in Germany, 1997
~
www.WorkshopManuals.co.uk 911 Carrera (996)
Manual transmission
-Actuation,
Detach the support bracket sleeves A and B at the support bracket. To do this, release the support bracket sleeves (presstabs in the direction indicated by the arrow) and carefully pull them out of the support bracket.
ass. housing
11. Unscrewtransmission/enginefastening screws. To do this, use a long 3/8 inch ex-
tension. Note
9. Placetransmission jack underthe transmission andfastenfixingstrap.
The engine may be lowered by up to 25 mm in order to improve accessibilityto the upper
screws.
10. Removetransmissionholderand transmission support.
1 8
~
2 i'
¥
3
~ 4
~
j.9S
~ 5
97.122 97-130
12. Pull transmissionto the front and lower it
carefully.
~"/\/
I
Installation Install in reverse order, observingthe following
/
points:
/
~--/ 97-123
34 35 19 Printed
Removing
in Germany
-4,
1997
and installing
transmission 996341
G 96
34 -5
.-~ r-~
www.WorkshopManuals.co.uk
Note Each time the shift cables are removed from the transmission lever, the retaining clips of the shift cable end pieces must be replaced. 1. Cleanteeth of the drive shaft and grease with a thin coat of Olista Longtime 3 EP (availableas spare part). 2. Ensure perfect seating of dowel sleeves in
crankcase. 3. Move in transmission so far that the clutch slave cylinder can be fitted. Tighteningtorque for hexagon-headbolts 23 Nm (17 ftlb.). 4. Carefullymove transmission in further and fasten to engine.
* Multiple-toothnut ** Hexagonnut (as of 4.9.97: M12 x 50 hexagon-headbolt) Tightening torques:
1
-,.
2,
8
#
7
~
;... I
~ -I: 4
i i
~ 151;
65 Nm (48 ftlb.:
Stabiliserto rear axle cross member side part (M8) =
23 Nm (17 ftlb.)
Drive shaft to transmission = flange (M10)
81 Nm (60 ftlb.)
Clutch slave cylinder to transmission (M8)
=
23 Nm (17 ftlb.)
Transmissionsupport to body (MID)
=
65 Nm (48 ftlb.)
!
" 3
Cross member to carrier = side member (MID)
5 97-130
Transmissionsupport/transmission carrier to transmissionbearing (M10) = 65 Nm (48 ftlb.) Transmissionsupport to body (MID)
34 -6
34 35 19 996341
=
Removing and installing
65 Nm {48 ftlb.:
transmission
G 96
Printed in Germany -4, 1997
www.WorkshopManuals.co.uk 911 Carrera (996)
34 08 19
Manual transmission -Actuation, ass. housing
Removingand installing shift console
Tools
600_96
litem
3408
Designation
Special tool
Lockingbridge
9619
19
Removing
Printed in Germany
-4,
1997
and installing
shift console 996347
Explanation
34 -7
-I' ~ /)
www.WorkshopManuals.co.uk
Removingand installing shift console
'I
j/
/-
2
;1iJ'
I~
/ /""'~ ...,/'
- / {~~::-:::~""l
/'
1 -Shift console 2 -Selector cable (blue) 3 -Shift cable (black)
34 -8
556_97
34 08 19 996347
Removing and installing shift console Printed in Germany -4, 1997
www.WorkshopManuals.co.uk 911 Carrera (996)
Manual transmission -Actuation, ass. housing
Removingand installing shift console Removal
Note The shift and selector cables must not be excessively bent or kinked. 1. Removecentre console (refer to Service No. 68 17 19). 2. Move shift lever to neutral position and fix shift lever with special tool 9619.
u 1 -Selector cable (blue) 2 -Shift cable (black) 3 -Adjuster open 4 -Adjuster closed 5 -Support bracket 6 -Locking sleeve
~ /
/~--
\ 1\
@~ 602-96
3. Remove shift console cover.
Removing and installing shift console
Printed in Germany
-4,
1997
5. Disengagesupport bracket sleeves (5) on the shift console. To do this, release the support bracket sleevesand carefullypull out of the support bracket. 6. Unscrewfastening nuts for the shift console and remove the shift console.
4. Disengagethe selector and shift cables on the shift console. To do this, slide the locking sleeves (6) forward as far as they will go and turn clockwise to removal position.
34 08 19
550_97
996347
34 -9
www.WorkshopManuals.co.uk Manual transmission -Actuation,
911 Carrera (996)
ass. housing
Installation Note The shift mechanismis designed so that installation and adjustmentare a single work step.
Preconditions for this are: Special tool 9619 must be fitted to fix the
shiftlever. The transmission must be in neutral. 1. Install the shift console and tighten the fastening nuts with 10 Nm (7.5 ftlb.).
2. Fastenshiftand selectorcableson the shift console: 1 -Selector cable (blue) 2 -Shift cable (black) 3 -Adjuster open 4 -Adjuster closed 5 -Support bracket
Fit support bracket sleeves (5) in the correct position. It must be possible to hear and feel them en-
603-1-96
gage.
3. Removespecialtool 9619 and shiftthrough all gearsas a test.
Engage shift and selector cables in the open adjusters (3) and close the adjusters(see enlarged view). The locking sleeves must move to the end
4. Clipin shiftconsolecover
position automatically.
5. Install centre console (refer to ServiceNo. 68 17 19).
34 -10
34 08 19 996347
Removing and installing shift console Printed in Germany -4, 1997
www.WorkshopManuals.co.uk 911 Carrera (996)
34 12 19
Manual transmission -Actuation, ass. housing
Removing and installing shift and selector cables
Tools
459_97
Item A
Designation
B
Lockingbridge
34 12 19 Printed
Special tool
Removaltool
9619
Removing and installing shift and selector cables
in Germany
-4,
1997
Explanation commerciallyavailable(refer to Technical EquipmentManual, Chapter2.4, No. 21)
996347
34 -11
~ ;.-1
www.WorkshopManuals.co.uk
Removing and installing shift and selector cables
~:?/ \
J/
; .;,.
~
I'
/~/
3
/,~~;~~
/,
/
(
/"'J
/7J
/ l
./
;"':" '":'
..-~
/
/~
555_97
1 -Selector cable (blue) 2 -Shift cable (black) 3 -Rubber sleeve
34 -12
341219
Removing and installing 996347
shift and selector cables Printed
in Germany
-4,
1997
~ ,~ /~--I
www.WorkshopManuals.co.uk 911 Carrera (996)
Manual transmission -Actuation, ass. housing
Removingand installing shift and selector cables Note The shift cable and selector cable can be exchanged only together I as they possess a common rubber sleeve.
4. Disengagethe selector and shift cables on the shift console. To do this, slide the locking sleeves (6) forward as far as they will go and turn clockwise to removalposition.
Removal Note The shift and selector cables must not be excessivelybent or kinked. 1. Removecentre console (refer to Service No. 68 17 19). 2. Lift shift console cover up and off.
3. Moveshiftleverto neutralpositionandfix shift lever with special tool 9619.
9619 1 -Selector cable (blue) 2 -Shift cable (black) 3 -Adjuster open 4 -Adjuster closed 5 -Support bracket 6 -Locking sleeve
~ \ 1\
@~ 602.96
55o_97
5. Disengagesupport bracket sleeves (5) on the shift console. To do this, release the support bracket sleevesand carefullypull out of the support bracket.
6. Removeparkingbrakeconsole. 7, Removeunderbodypanel (middle and rear),
34 12 19
Removing and installing shift and selector cables
Printed in Germany
-4,
1997
996347
34 -13
www.WorkshopManuals.co.uk Manual transmission -Actuation, ass. housing
8. Disengage shift and selector cables on the transmission:
9. Removecrossmember. 10. Place transmissionjack under the transmission and remove transmissionsupport.
-
554_97
97.122
Lever off shift and selector cables (1/2) using a commerciallyavailableremoval tool (refer to Technical EquipmentManual, Chapter 2.4, No. 21). Disengagesupport bracket sleeves (A!B) on the support bracket. To do this, release the support bracket sleeves (press tabs in the direction indicated by the arrow) and carefully pull them out of the support bracket.
97-123
~ ~
911 Carrera (996)
34 -14
34 12 19
Removing and installing shift and selector cables 996347
Printed
in Germany
-4,
1997
www.WorkshopManuals.co.uk 11. From the passenger compartment,press rubber sleeve out to the rear and pull B+ wire out of the slotted sleeve.
Installation Note Each time the shift cables are removed from the transmission lever, the retaining clips of the shift cable end pieces must be replaced.
1. Positionrubbersleeve.
55~97
1 -Rubber sleeve
553_97
2. Apply a generous coating of lubricant(e.g. Contifixtyre mounting paste) on the rubber sleeve and B+ wire in the area of the body opening. 3. Push shift and selector cables through the body openingfrom behind. Take care not to soil the vehicleinterior.
34 12 19 Printed
Removing and installing shift and selector cables
in Germany
-4,
1997
996347
34 -15
~ .-
www.WorkshopManuals.co.uk
4. Insert B+ wire into the slot of the rubber sleeve and press sleeve into the body opening.
Note The shift and selector cables are routed underneaththe console.
8. Fastenshiftandselectorcableson the shift console: Fit support bracket sleeves (5) in the correct position. It must be possible to hear and feel them engage. Engage shift and selector cables in the open adjusters (3) and close the adjusters (see enlargedview). The locking sleeves must move to the end position automatically. 1 -B+ wire 2 -Rubber sleeve 3 -Shift and selector cables
551_97
5. Fasten shift and selector cables on support bracket (AjB) and on transmission lever (1/2).
~~
/
~,
('9""l'
'-~
'..
.
1 -Selector cable (blue) 2 -Shift cable (black)
1 -Selector cable (blue) 2 -Shift cable (black) 3 -Adjuster open 4 -Adjuster closed 5 -Support bracket
554_97
6. Installtransmissionsupportandcross member.
603-1-96
9. Removespecialtool 9619 and shiftthrough all gearsas a test.
7. Installparkingbrakeconsole. 10. Clipin shiftconsolecover.
34 -16
341219
Removing and installing shift and selector cables 996347
Printed in Germany
-4,
1997
www.WorkshopManuals.co.uk 911 Carrera (996)
Manual transmission
-Actuation,
alss. housing
11. Adjust parking brake (refer to Service No. 46 83 16),
12. Install centre console (refer to Service No. 68 17 19). 13. Fit underbodypanels (middle and rear),
Tightening torques: Parking brake console to = body (M8)
23 Nm (17 ftlb.)
Transmissionsupport to body (MID)
65 Nm (48 ftlb.
=
Transmissionsupport/transmission carrier to transmission bearing (MID) = 65 Nm (48 ftlb.J Cross member to carrier = side member (MID)
34 12 19 Printed
65 Nm (48 ftlb.]
Removing and installing shift and selector cables;
in Germany
-4,
1997
996347
34 -17
B
www.WorkshopManuals.co.uk 35 50 19
Removingand installing sealing ring for input shaft
c 117.97
Designation
Special tool
A
Sleeve
9255
B
Puller
9629
C
Pressure piece
9628
Item
35 50 19
Explanation
Removing and installing sealing ring for input sh,aft
Printed in Germany, 1997
996351
35 -1
www.WorkshopManuals.co.uk
Removingand installing sealing ring for input shaft Removal
1. Removetransmission (see Page 34 -3).
5. Pull out sealing ring by screwing in the hexagon-headscrew.
2. Removethe release lever for clutch. 3. Removeguide tube for release bearing.
/
\.
4. Screw special tool 9629 securelyinto the
/i',(~
sealingring.
u
/
~
140.97
Note
139.97
35 -2
35 50 19
The coil spring must be pulled off the input shaft with a wire hook if the spring shouldjump down when removing the sealingring.
Removing and installing sealing ring for input shaft 996351
Printed in Germany, 1997
'~II
www.WorkshopManuals.co.uk 911 Carrera (996)
Manual transmission
-Gears,
shafts, into gearsh.
Installation 1. Push assembly sleeve 9255 onto the toothing
3. Drive in sealing ring with special tool 9628 as far as the mountingface.
of the input shaft.
-
~,
~ ~, 141.97
2. Fill the space between the dust and sealing lips on the sealing ring with grease (e.g. Liqui
142.97
4. Install guide tube for release bearing. Always renewfastening screws and tighten with 24 Nm (18 ftlb.)
Moly).
5. Fit release lever with release bearing. 6. Clean teeth of the input shaft and grease with a thin coat of Olista Longtime 3 EP (available as spare part).
35 50 19
Removing and installing sealing ring for input shaft
Printed in Germany, 1997
996351
35 -3
www.WorkshopManuals.co.uk 911 Carrera (996)
39 20 19
Final drive -Differential,
differential
lock
Removing and installing cover for final drive
Tool
137.97
Item
Designation
Special tool
Explanation
Centeringpins
9321
M8
39 20 19
Removing and installing cover for final drive
Printed in Germany, 1997
996391
39.1
www.WorkshopManuals.co.uk
Removing and installing cover for final drive Removal
Installation
1. Draintransmissionoil.
Tightening torques:
2. Removedrive shaft at the transmissionand protect the shaft against damage (use scrap pieces of hose with a diameter of 30 mm).
Cover for final drive to transmission (M8)
=
25 Nm (18 ftlb.)
Drive shaft to transmission 3. Removehalfshaftflange (see Pages 39 -5 and 39 -9).
flange (MID)
=
81 (60 ftlb.)
=
30 Nm (22 ftlb.:
Oil filler and oil drain 4. Unclip hydraulic line for clutch slave cylinder.
plugs (M22)
5. Unscrewhexagon-headbolts for cover and press off cover on alternate sides.
1. Fit sealing ring untwisted. 2. Coat sealing ring with transmissionoil and fit cover. Use special tool 9321 to aid assembly.
~
13~V
-lni
(
-129.97
39 -2
39 20 19 996391
Removing and installing cover for final drive Printed in Germany, 1997
www.WorkshopManuals.co.uk
39 22 19
Sealing ring for limited-slip differential-Removing.andinstalling the halfshaft flange
Tool
143.97
Item
Designation
Special tool
Pressure piece
9252
Explanation
www.WorkshopManuals.co.uk Final drive -Differential,
differential
lock
911 Carrera (996)
Sealing ring for limited-slip differential --Removing and installing the halfshaft flange
r4 \~~~!~t:f~==v=v=v:
~
3
1 -Hexagon-head bolt 2 -Halfshaft flange 3 -Sealing ring
39 -4
1 2
115-97
39 22 19 996391
Sealing ring for limited-slip differential Printed in Germany. 1997
. ~
www.WorkshopManuals.co.uk 911 Carrera (996)
Final drive -Differential,
differential lock
Sealing ring for limited-slip differential --Removing and installing halfshaft flange Note
Installation
The sealing rings can also be replaced with the transmission installed.
1. Fill the space between the dust and sealing lips with grease (e.g. Liqui -Moly) and drive in the sealing ring up to the mountingface using special tool 9252.
Removal 1. Unscrewfasteningscrewfor halfshaftflange and pull out halfshaftflange.
/
;=(~ I
r
114.97
2. Tighten the fastening screw for the halfshaft flange with 44 Nm (33 ftlb.).
113 -97
2. Lever out sealing ring using a suitabletool
39 22 19
Sealing ring for limited-slip differential
Printed in Germany, 1997
996391
39 -5
www.WorkshopManuals.co.uk 911 Carrera (996)
39 22 19
Final drive -Differential,
differential lock
Sealing ring for differential.. Removingand installing halfshaft flallge
Tool
A amI-
~~~~~:~~~~~~;;~~~
c
B
128-97
Designation
Special tool
A
Pull-intool and extractor
P 254
B
Pressure piece
9252
c
Pressure piece
9247/1
Item
39 22 19
Sealing ring for differential
Printed in Germany, 1997
--Removing 996391
Explanation
and ins1:alling halfshaft flange
39 -7
www.WorkshopManuals.co.uk Final drive -Differential,
differential
lock
911 Carrera (996)
Sealing ring for limited-slip differential --Removing and installing halfshaft flange
1 -Halfshaft flange 2 -Sealing ring 3 -Snap ring
39 -8
39 22 19
116.97
Sealing ring for differential 996391
--Removing
and installing
halfshaft flange
Printed in Germany, 1997
www.WorkshopManuals.co.uk 911 Carrera (996)
Final drive -Differential,
differential lock
Sealing ring for limited-slip differential --Removing and installing halfshaft flange Note The sealing rings can also be replaced with the transmission installed. Removal 1. Remove right halfshaftflange. To do this, place a chisel or spacer "A"under the halfshaftflange and pullout the halfshaft flange by turning the screw "B".
135.97
2. Lever out sealing ring using a suitabletool.
134.97
Note Pull out left halfshaftflange by screwing in the hexagon-headbolts "A"on alternate sides. The bolts must be supported on the rib reinforcements of the cover (see Figure).
39 22 19
Sealing ring for differential
Printed in Germany, 1997
--Removing 996391
and installing
halfshaft flange
39 -9
www.WorkshopManuals.co.uk Final drive -Differential,
differential
lock
911 Carrera (996)
Installation 1. Fill the space between the dust and sealing lips with grease (e.g. Liqui -Moly) and drive in the sealing ring up to the mountingface using special tool 9252.
3. Greasethe snap ring well and drive in the halfshaftflange using the special tools P254 and 9247/1.
2. Always replace the snap ring for the halfshaft flange, To do this, clamp the flange in the vice with protective jaws and press out the snap ring with the new snap ring "A",
\
136.97
~'\ A -New
39 -10
snap ring
39 22 19
175.97
Sealing ring for differential 996391
--Removing
and installing
halfshaft flange
Printed in Germany, 1997
www.WorkshopManuals.co.uk
Technical Manual 9..?? ~"7'~~
.4 (996)
Transmission,manualtransmission
Trennbl.chp
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
Contents
3
Transmission, manual transmission
3
Power transmission
3
Technical data. ..
39
Final
39 88 19 39 02 19 39 82 19 39 60 19 39 6001 39 59 19
58 19 39 90 55 39 62 19 39
3
drive
3 -101
-Differential,
Removing
and
installing
Checking Removing
function and
Changing Removing
oiland for installing final
installingof
differential
cardan sealing front
lock
final shaft. ring drive.for
cardan
flange.
for clutch. flanged
shaft.
installedviscous sealing
viscous ring clutch.
drive. support cover
for for final final
drive.drive.
in Germany
39 -121
39-125 39-127
101
Transmission, manual transmission
Printed
.
39-101 39-105 39-109 39-113 39-117 39-119
-18,
1998
C4STOC
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
Transmission
8 3
Technical data
6-speed manual transmission 696/30
301_98
Type
Code letter
G96/30
3
Equipment
Installed in
Model year
6-speed
911 Carrera 4 (996)
1999
3 -101
Technical data
Printed in Germany -14, 1998
C4S3_101
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
3
Transmission
Technical data
Key to transmission numbers
303_98
G96/30
--r
1
001014
T
Transmission type
T
Index for version within transmission number
Serial number
1 = normal differential
3
3 -103
Technical data
Printed in Germany -14, 1998
C4S3_101
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
Transmission
3
Technical data Manual transmission G96/30
3
Technical data
Printed in Germany -14, 1998
3 -105 C4S3_101
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
Transmission
Technical data Tightening torques (manual transmission G96j30)
Screwplug, oil drainage and oil filling
M22
30 (22)
flange
MID
81 (60)
Clutch slave cylinder on transmission
M8
23 (17)
Guidetube for release bearingon transmission
M8
24 (18)
Ball journal for release lever on transmission
M8
25 (19)
Cover for final drive on transmission
M8
25 (19)
MI2 MID
85 (63) 45 (33)
Reversinglightswitch on transmission
M12
15 (11.0)
Bracket for shift cables on transmission
MID
45 (33)
Cardanflangeon transmission
M20
Driveshafton transmission
Transmission on engine
120 (89) *
* Counter collar nut with 170 Nm (126 ftlb.), loosen again and tighten to 120 Nm (89 ftlb.) (refer to Servo No. 39 82 19).
3
Technical
3 -107
data
Printed in Germany -14, 1998
C4S3_101
"
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
3
Transmission
3
Technical data
Final drive Z96jOO
0 /
~
"'
\l
li- .-1\
'~--
--
.-" 'I~-
"
278_98
Type
Code letter
Z96jOO
3
Equipment
Installed in
Model year
911 Carrera 4 (996) world-wide
1999
Technical data
Printed in Germany -14,
3 -109 1998
C4S3_101
.
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
Transmission
3
Technical data Tightening torques, final drive Z96/00 Location
Thread
Tightening torque Nm (ftlb.)
Screw plug, oil drainage and oil filling
MI8
28 (21)
Lid on final drive
M8
25 (19)
Longileck tube on final drive
M8
25 (19)
Driveshafton final drive
M8
39 (29)
MIa x 90
65 (48)
on body
MID
65 (48)
Front transmission support on front-axle cross member
MID
65 (48)
Stud on front-axle cross member
M8
20 (15)
Front transmission support on final drive
MID
65 (48)
Rear transmission support on transmission mount Rear transmission support
3
3 -111
Technical data
Printed in Germany -14, 1998
C4S3_101
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
39 88 19
Final drive -Differential,
Removing and installing front final drive
1 -Front final drive 2 -Long-neck tube with central shaft 3 -Cardan shaft 4 -Transmission support, rear 5 -Transmission support, front
39 88 19
differential lock
Removing
and installing
Printed in Germany -14, 1998
249_98
front final drive C4S39101
39 -101
www.WorkshopManuals.co.uk Final drive -Differential,
differential lock
911 Carrera 4 (996)
Removing and installing front final drive Removal 1. Removecardan shaft (refer to Serv. No. 39 02 19).
6. Removepipe holder and unscrewfastening screws/nuts for the rear transmissionsupport.
2. Removeunderbodycover(front).
Note Do not undo screw "C"
3. Removediagonal braces at front and cover.
A -Diagonal braces B -Cover
243_98
A -Pipe holder B -Transmission support C -Screw
244_98
4. Removedrive shafts at the transmissionand protect the shafts against damage (use scrap pieces of hose with a diameter of 30 mm).
8
Note
To protect the coolant pipes against scratches when the final drive is removed or installed, it is advisablethe protect the pipes with adhesive tape in the area of the final drive.
5. Placetransmission jack underthe transmissionand securewithfixingstrap.
8 39 -102
3988 19 C4S39101
Removing and installing front final drive Printed
in Gennany
-14,
1998
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
Final drive -Differential,
7. Undo fastening nuts for front transmission support and unscrewthe studs.
differential lock
Installation
Installin reverseorder, observingthe following points:
::::::=
j;~
1. Carefullylift in the transmission with a universaltransmissionjack. Whendoing so, do not damage the coolant pipes.
~I ~,
A
~.::' .If
CD
~-l';:;;:~~
A -Transmission support B -Hexagon nut C -Stud
245_98
8. Carefullylower the transmissionout. Whendoing so, avoid damaging the coolant pipes.
250_98
2. Push studs through the front transmission mounts and screw into the front-axlecross member.
3. Fastentransmission mountson the front-axle crossmemberandon the body. Note If the hexagon-headbolt (Mlax gO) was undoneon the rear transmissionsupport,! transmission mount, it is importantto tighten the front transmissionsupport first, then the rear transmissionsupport and the MIa x gO screw on the rear transmission mount last.
39 88 19 Printed
Removing and installing front final drive
in Germany
-14,
1998
C4539101
39 -103
www.WorkshopManuals.co.uk Final drive -Differential,
differential lock
911 Carrera 4 (996)
Tightening torques: Studs on front-axle cross member (M8)
= 20 Nm (15 ftlb.)
Front transmission support on transmission (MID)
= 65 Nm (48 ftlb.)
Front transmission support on front-axle cross member (MID)
= 65 Nm (48 ftlb.)
Rear transmission support on body (MID)
= 65 Nm (48 ftlb.)
Rear transmission support on transmission mount (MlOx 90)
= 65 Nm(48 ftlb.)
Drive shafts on frontaxle final drive (M8)
= 39 Nm (29 ftlb.)
Diagonalbraces on body and front-axle cross member (M12)
= 100 Nm (74 ftlb.)
Tankstrap on body (M8 x 40)
= 23 Nm (17 ftlb.)
Pipe holder on transmission support (M6)
=
7 Nm (5.0 fttb.)
8 39 -104
39 88 19 C4S39101
Removing and installing Printed
front final drive
in Germany
-14,
1998
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
39 02 19
Final drive -Differential,
differential lock
Removing and installing cardan shaft
Tools
237_98
Item
Designation
Special tool
Assemblysleeve
9255
39 02 19
Removing and installing cardan shaft
Printed in Germany -14, 1998
C4S39105
Explanation
39 -105
~~: \" ~
www.WorkshopManuals.co.uk
Removingand installing cardan shaft Removal Note
,,/
Observe max. joint angle of 200 when removing and fitting. Furthermore,the cardan joint must not be loaded at max. deflection (stop).
./
j)
1. Remove underbodycovers (rear and centre), 2. Support manualtransmission in installation position with the transmissionjack and remove the transmissionsupport.
1/
"
I
)
I
'"
~
I
\,~
:::-:
//...>
/ /
B -Transmission holder
~ ~ ,.
~~ '"
'.,A
226_98
3. Fastentransmission to the transmissionholder withthe two fasteningscrews. 4. Detach cardan shaft at the transmissionside and press it off the transmissionflange with two mountinglevers.
~
'"
A -T ransm;ss;on support
225_98
227_98
5. Pullcardanshaftout of the splinesof the centralshaftandremove. 6. Removebellowsfrom the centralshaft.
39 -106
39 02 19 C4S39105
Removing and installing
cardan shaft
Printed in Gennany -14, 1998
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
Final drive -Differential,
I
differential
lock
Installation
Installin reverseorder, observingthe following points: 1. Alwaysreplacebellowsfor cardanshaft. 2. Slide assemblysleeve 9255 over the shaft splines, lightly lubricate sleeve with Vaseline and push on the bellowsto the stop.
i 01
~'
( \ n
235_98
A A -Assembly sleeve 9255
3902 19 Printed
Removing and installing cardan shaft
in Germany
-14,
1998
C4S39105
236_98
39 -107
www.WorkshopManuals.co.uk Final drive -Differential,
differential
911 Carrera 4 (996)
lock
3. Grease bushingwith approx. 3 g of Olista
Longtime 3EP.
A -Bellows B -Cardan shaft C -Central shaft groove
240_98
Tighteningtorques: Cardan shaft on transmission flange (MID) = 45 Nm (33 ftlb.) A -Bushing
238_98
4. Grease splines of the cardan shaft with Olista Longtime 3 EP. Slide shaft into the central shaft splines and fit on the transmissionside.
Transmissionsupport; transmissioncarrier on transmission mount (M 10) =
65 Nm (48 ftlb
Transmissionsupport 5. Push bellowsforward until it engagesin the groove of the central shaft. Check whether the bellows is seated properly by pulling on it.
on body (MID)
=
65 Nm (48 ftlb.)
8
39 -108
39 02 19 C4539105
Removing and installing
cardan
shaft
Printed in Gennany -14, 1998
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
39 82 19
Final drive -Differential,
differential lock
Removingand installing sealing ring for cardan flange
Tools
276_98
Item
Special tool
Designation
Explanation commerciallyavailable (refer to Technical Equipment Manual,Chapter 2.4, No. 64).
A Socketwrenchinsert
9639
B Pressure piece
Commercially available (refer
C Three-armpuller
to Technical Equipment Manual, Chapter 2.4, No. 112-1)
39 82 19 Printed
Removing and installing sealing ring for cardan flange
in Germany
-14,
1998
C4S39109
39 -109
~
www.WorkshopManuals.co.uk Final drive -Differential,
differential
lock
911 Carrera 4 (996)
Removing and installing sealing ring for cardan flange Removal 1. Removecardan shaft (refer to ServoNo. 3902 19).
\ \. I
2. Place oil collection tray under the transmission.
3. Engagea gear and firmlyset the handbrake. 4. Removecollar nutwith a long aff 30 socket wrenchinsert(referto WorkshopEquipment Manual,Chapter2.4, No. 64).
"
\
/
I \. / fflYA
:..:.~
0
j\
265_98
~~
0
~ /
~
,...;;::::
0
~
\\~\ 264_98
5. Pull off the cardan flange with a three-arm puller (refer to Workshop EquipmentManual, Chapter2.4, No. 112-1).
39 -110
39 82 19
Removing and installing C4S39109
sealing ring for cardan flange Printed in Gennany -14, 1998
www.WorkshopManuals.co.uk
Installation
6. Removesealing ring. To do this, use an angle drill to make a 3.5 mm dia. hole in the lowest non-rubberisedsurface "B". Screw in a large sheetmetal screw (4.8 x 25) with a large washer and lever out the sealing ring with two screwdrivers.
1. Removedrilling chips in the transmissionneck. 2. Degreasethe pinion shaft journal (splinesand thread), halfshaftflange splinesand thread of the collar nut with cleaning agent (e.g. Loctite quick cleaner). 3. Fill the space betweenthe dust and sealing lips on the sealing ring with grease (e.g. Liqui -Moly) and drive in the sealingring up to the mountingface using special tool 9639.
""
~ B
~
J/
>"
A -Sheetmetal screw 4.8 x 25 B -3.5 mm bore
"" '"
273_98
"""
/"
'""
1\ II
II
274_98
4. Coat halfshaftflange splineswith screw locking lacquer (e.g. Loctite 243 or Omnifit50 M) and fit the flange. 5. Coat contact surface and thread of the collar nut with screw locking lacquer (as in step 4).
39 82 19 Printed
Removing and installing sealing ring for cardan flange
in Germany
-14,
1998
C4S39109
39 -111
www.WorkshopManuals.co.uk Final drive -Differential,
differential
lock
911 Carrera 4 (996)
6. Counter collar nut with 170 Nm (126 ftlb.), loosen again and tighten to 120 Nm (89 ftlb.).
1 -Halfshaft flange 2 -Collar nut A -Screw locking lacquer (Loctite 243 or Omnifit 50 M)
275_98
7. Check transmission oil (refer to ServoNo. 39 90 55).
39 -112
39 82 19
Removing and installing sealing ring for cardan flange C4S39109
Printed
in Gennany
-14,
1998
www.WorkshopManuals.co.uk 911 Carrera 4 (996)
39 60 19
Final drive -Differential,
differential
lock
Removingand installing the viscous clutch
Tools
8
.
257_98
Item
Special tool
Explanation
A Assemblyaid
9638
2 parts
B Holdingrail
VW457
Drill two 10.5 mm holes
Designation
39 60 19 Printed
Removing and installing the viscous clutch
in Germany
-14,
1998
C4539113
39 -113
www.WorkshopManuals.co.uk Final drive -Differential,
differential
lock
911 Carrera 4 (996)
Removingand installing the viscous clutch
3 /
~.-
:",,-; "',~
i
---\1 ! i
I.I-I-.~
2
.-I¥ '~::G-~.j;
--- ---
r-- --36
"
!
J
r-- 29
35
$
34 I ~
28
Q-30 0-31 /
0 .
14
I
27 I
"
26 1.
0
25
24 I
I
:C]g
-t~~
13
,0
f/(33 ~
!
32 \ ~ r."--
I
O-
I
I I
-~ ~J
.--16
$
~-17 1-18
\
1t
/"'
21Y/l
15
~U
12
11
I
9:
-l
I
3
@--
!~ ""f-1J
i~ 172_99
~ r:~ ~ 8 10
6
34 -210
34 35 37
Disassembling GT334209
and assembling Printed
transmission in Germany -29,
-GT3 1999
www.WorkshopManuals.co.uk 911 Carrera
(9961
Manual transmission
-Actuation,
ass. housing
Note:
No.
Removal
Qty.
Designation
1
Hexagon-headbolt
2
Fronttransmissioncase
Installation
10
Tighten to 25 Nm (19 ftlb.)
1
Seal with Loctite 574
cover 3
4
5
Hexagonnut (self-locking)
1
Hexagonnut (self-locking)
1
Innerbearingrace
Fix the drive shaft with specialtool 9253 and shift into a gear
Always replace.
Fix the drive shaft with special tool 9253 and shift into a gear
Always replace. Tighten to 200 Nm
Pull off via fixed gearwheel
Heat to approx. 120°C
Tighten to 300 Nm
(222 ftlb.)
(148 ftlb.)
No.6 6
Fixedgearwheel(reverse
1
gear)
7
Spacer sleeve
8
Cylindrical-roller bearing
1
9
Thrust plate
1
Loose gearwheel(reverse
1
10
Pull off via loose gearwheel No. 10
Heatto approx. 120°C
Mark for refitting
Checkfor wear. Fit with the same gear wheel (nubsfacing the driver
gear)
11
Synchronisingring
1
dogs)
12
Needlecage
1
13
Hexagon-headbolt
2
14
Washer
2
15
Shiftcollar
1
Mark for refitting
Fit with the same gear whee! Tightento 18 Nm (13 ftlb.)
Shift into a gear and removetogether with shift fork No. 19. Do not lose the synchronisingcompo-
Dotting marks centred with respect to the driver dogs. Stepped side faces loose gearwheelNo. 10
nents 16
Driver dog
3
17
Ball
3
34 35 37 Printed
Disassembling
in Germany
-29,
1999
Curvedside faces the shift collar
and assembling transmission GT334209
-GT3
34- 211
www.WorkshopManuals.co.uk Manual transmission -Actuation, ass. housing
911 Carrera (996)
Note: No. Designation
Removal
Qty.
18
Spring
3
19
Shift fork (reverse gear)
1
20
Inner race *
1
Installation
Fix shift rod with special tool 9650. Then adjust it so that just enough play remains at the shift collar when reverse gear is engaged. The synchronising ring must be free to rotate in idle position Mark for refitting. Pull off via guide sleeve No. 21
Fit with the same gear wheel. Heatto approx.
120°C 21
Guidesleeve (with snap ring)
1
Open side of the snap ring must not lie in the area of the driver dogs. Fit in correct position with shift collar and shift fork (snap ring facing loose gearwheelNo. 24)
22
Fixedgearwheel(5th gear)
1
Do not confuse with fixed gearwheelNo. 37. Large collar faces spacer sleeve No. 23
23
Spacer sleeve
24
Loose gearwheel(5th gear)
1
Do not confuse with loose gearwheelNo. 35
25
Synchronisingring
1
Mark for refitting
Checkfor wear. Fit with the same gear wheel (nubsfacing the driver dogs)
26
Needlecage
1
Mark for refitting
Fit with the same gear wheel
27
Inner race *
1
Mark for refitting. Pull off via loose gearwheelNo. 35 using arms of specialtool 9284
Fit with the same gear wheel. Heatto approx.
34 -212
34 35 37
Disassembling GT334209
120°C
and assembling
transmission
Printed in Germany
-29,
-GT3 1999
www.WorkshopManuals.co.uk Manual transmission -Actuation, ass. housing
911 Carrera (996)
Note:
No. Designation 28
Removal
Qty.
Installation
1
Shift collar
Dotting marks centred with respect to the driver dogs.
29
Driver dog
3
30
Ball
3
31
Spring
3
Shift fork
1
32
(5th and 6th gears)
Curvedside faces the shift collar
Fix shift rod (5th and 6th gears) by shifting into a gear
33
Guidesleeve
1
34
Synchronising ring
1
Adjust. In idle position, the shift collar must be preciselycentred between the loose gearwheels Put on together with shift collar and shift fork
Mark for refitting
Checkfor wear. Fit with the same gear wheel (nubsfacing the driver dogs)
35
Loose gearwheel(6th gear)
1
36
Needlecage
1
37
Fixedgearwheel(6th gear)
1
Do not confuse with loose gearwheelNo. 24 Mark for refitting
Fit with the same gear wheel Do not confuse with fixed gearwheelNo. 22 Large collar faces spacer sleeve 23
* As the bearing inner races (No. 20 and 27) are subjectto tolerances(transitionfit), they could have a loose or tight fit on the shaft.
34 35 37
Disassembling
Printed in Germany
-29,
1999
and assembling
transmission GT334209
-GT3
34 -213
www.WorkshopManuals.co.uk Manual transmission -Actuation, ass. housing
911 Carrera
(996)
Disassembly and assembly instructions Disassembly Note The locking elements or balls of the shift rod lock will fall out without being noticed if the shift rods are moved past the neutral lock or gear lock when the transmissionis disassembledor assembled.
145_99
2. Shift into a gear, fix the drive shaft with special tool 9253 and unscrew the hexagon nuts for the pinion shaft and drive shaft.
4 and 7 = Intermediatelocking elements
320_99
1. Fastentransmissionon the assemblysupport with special tool P201 and drain the oil.
146_99
34 -214
34 35 37
Disassembling GT334209
and assembling
transmission
Printed in Germany
-29,
-GT3 1999
www.WorkshopManuals.co.uk 911 Carrera
Manual transmission -Actuation, ass. housing
(996)
3. Fix shift rod for 5th and 6th gears by shifting into a gear and pull off the needlebearing inner race.
2. Shift into a gear and fit all gear wheels. 3. Move the shift rods for 5th/6th gear and reverse gear to installationposition and adjust the shift forks. 4. Adjust shift fork for reverse gear. To do this, fix the shift rod with special tool 9650. Then adjustthe fork so that just enough play remains at the shift collar when reverse gear is engaged.The synchronising ring must be free to rotate in idle position.
\\"L, A -Arms of puller 9284 B -Pressure piece 9656
147_99
J
Assembly 1. Check synchronisingrings by pushingthem onto the gear wheels and measuringthe gap "A" with a feeler gauge. Installation dimension (new) Wear limit
0 J.
"",((
=i min. 0.9 mm =10.6...0.7 mm l
Dol])
,.,~
A -Special tool 9650 B -M6xll 0 screw
315_99
\'\ \\\
313_99
34 35 37 Printed
Disassembling
in Germany
-29,
1999
and assembling
transmission GT334209
-GT3
34 -215
www.WorkshopManuals.co.uk 911 Carrera
(9961
34 35 37
Manual transmission
-Actuation,
ass. housing
Disassembling and assembling transmission
2 216_99
34 35 37 Printed
Disassembling and assembling transmission
in Germany
-29,
1999
GT334217
34 -217
www.WorkshopManuals.co.uk
No. Designation 1
Hexagon-head bolt
2
Note:
Removal
Qty.
Installation
12
Tightento 25 Nm (19 ftlb.)
Gear housing
1
Roller of the shift catch must engage in the driver of selector shaft No.9. Seal with Loctite 574
3
Cylindrical-roller bearing
1
Heatto approx. 120°C
4
Shift rod (reverse gear)*
1
See Page 34 -221
5
Intermediatelocking element
1
Do not lose
6
Shift rod (5th and 6th
1
See Page 34 -221
Insert with viscous grease
gears)*
7
Intermediate locking element
1
Same as No.5
Same as No.5
8
Locking element
1
Same as No.5
Same as No.5
9
Selector shaft
1
Do not lose rollers
Fit rollers with viscous grease
10
Inner race
Mark for refitting. Pull off via loose gearwheelNo. 14
Fit with the same gear wheel. Heatto approx.
120°C
11
Thrust plate
1
12
Cylindrical-rollerbearing
1
13
Thrust plate
1
14
Loose gearwheel(1st gear)
1
15
Friction ring
1
Mark for refitting
Fit with the same gear wheel
16
Tapered ring
1
Mark for refitting
Fit with the same gear wheel. Lugs must engage in the cut-outs on the loose gearwheel
34 -218
Heatto approx. 120°C
34 35 37 Disassembling and assembling transmission Printed in Germany -29, 1999 GT334217
1
www.WorkshopManuals.co.uk
Note:
No. Designation 7
Qty.
Removal
Installation
Synchronising ring
1
Mark for refitting
Checkfor wear. Fit with the same gear wheel. Drivers must engage in the cut-outs on the conical ring gearwheel.The nubsface the driver dogs
18
Needle bearing
1
Markfor refitting
Fit with the same gear wheel
19
Inner race
Shift rods in idle position. Pull off via loose gearwheel No. 30 Mark for refitting
Fit with the same gearwheel. Heatto approx.
20
Shift rod/shift fork (1st and 2nd gears)*
21
Locking element
1
22
Shift collar (with asymmetrically pointed teeth)
1
23
Driver dog
3
24
Ball
3
25
Spring
3
26
Guidesleeve
1
34 35 37 Printed
See Page 34 -221. Removewith shift collar No. 22 Same as No.5
-29,
1999
Sameas No.5 Insert in correct position with guide sleeve and shift rod. The tooth gap inside the guide sleeve must be preciselyaligned with the oil bore of the pinion shaft.
The tooth gap inside the guide sleeve must be precisely alignedwith the oil bore of the pinion shaft
Disassembling and assembling transmission
in Germany
120 °C
GT334217
34 -219
1
www.WorkshopManuals.co.uk
Note:
No.
Designation
Qty.
Removal
Installation
Mark for refitting
Checkfor wear. Fit with the same gear wheel. Drivers must engage in the cut-outson the conical ring gearwheel.The nubsface the driver dogs
Mark for refitting
Fit with the same gear wheel. Lugs must engage in the cut-outson the loose gearwheel
Mark for refitting
Fit with the same gear wheel
27
Synchronisingring
28
Taperedring
29
Friction ring
1
30
Loose gearwheel(2nd gear)
1
31
Needlebearing
1
Mark for refitting
Fit with the same gear wheel
32
Inner race
1
Mark for refitting. Pull off via fixed gearwheelNo. 34
Fit with the same gear wheel. Heatto approx.
1
120°C 33
Thrust plate
1
34
Fixedgearwheel(3rd gear)
1
35
Spacer sleeve
36
Hexagonnut
37
Hexagon-headbolt
6
38
Tensioningplate with gear set*
1
See rage 34 -221
39
Adjusting shim (S3)
x
Note the quantityand thicknessfor reinstallation
40
Screw plug
4
41
Spring
4
42
Ball
4
34 -220
Large collar faces thrust plate No. 33
Tightento 25 Nm (19 ftlb.) Tighten to 25 Nm (19 ftlb.)
Remeasure if necessary Tightento 12 Nm (9 ftlb.
34 35 37 Disassembling GT334217
and assembling Printed
transmission
in Germany
-29,
1999
www.WorkshopManuals.co.uk
Note:
No. Designation
Qty.
43
Oval-headscrew
44
Guidetube
45
Shaft seal
Removal
2
1
Installation Tightento 10 Nm (7.5 ftlb.)
See ServoNo. 35 50 19
Install only after fitting the gear set
46
Transmission housing
1
* If the differential is still installed,the locking pieces (Nos. 40, 41, 42) must be taken out before the shift rods (Nos. 4, 6, 20) and tensioningplate (No. 38) can be removed.
Note As the bearing inner races (Nos. 10, 19 and 32) are subjectto tolerances (transitionfit), they could have a loose or tight fit on the shaft.
34 35 37 Printed
Disassembling
in Germany
-29,
1999
and assembling
transmission GT334217
34 -221
www.WorkshopManuals.co.uk
Disassembly and assembly instructions Disassembly In the interest of simplifyingthe work, the complete gear set is not removed. Instead, the pinion shaft is partiallydisassembledwhile still installed.
2. Check synchronisationof 1st and 2nd gears. To do this, place the friction ring and the synchronisingring in the correct position on the gear wheel. Measuregap dimension"A" with a feeler gauge. Installationdimension(new) = 1.5...2.0 mm = 1.2 mm Wear dimension
Note
The locking elementsor balls (No. 42) of the shift rod lock will fall out without being noticed if the shift rods are moved past the neutral lock or gear lock when the transmission is disassembled or assembled(also see Pages 34 -221 and 34 -214). Tap the gear housingwith a plastic hammer to detach it from the transmission housing, and press the roller of the shift catch out of the selector shaft driver.
A v'
\\
Assembly 1. Apply some grease on the adjusting shimsto the correspondingthickness and "glue" them onto the housing(use the number of adjusting shims "S3" noted during disassemblyor the number of adjustingshims as calculated during adjustmentof the drive pinion).
4. Tightentensioningplate fastening screw to 25 Nm (19 ftlb.).
~
" \, ::~ \
1::\
1(/
~""
~~
34 -222
3. Installthe completelypreassembledgear set.
---I:~~
(---
A -Adjusting
313_99
shim "$3"
~
II~~ 380_99
34 35 37 Disassembling GT334217
and assembling Printed
transmission
in Germany -29,
1999
www.WorkshopManuals.co.uk 911 Carrera
(996)
Manual transmission
-Actuation,
5. Fit shift collar onto the guide sleeve so that the dotting marks "B" are centred with respect to the balls. Additionally,the recognitiongroove "A" around it must face the 2nd gear.
A = Recognitiongroove (must face the 2nd gear)
ass. housing
6. Observeinstallationposition of the locking elements.
324_99
1 = Shift rod for 3rd and 4th gears 2 = Lock (short) 3 = Shift rod for 5th and 6th gears 4 = Intermediatelock 5 = Lock (long) 6 = Shift rod for reverse gear 7 = Intermediatelock 8 = Lock (short) 9 = Shift rod for 1 st and 2nd gears
320_99
Note
Do not move the shift rods past the neutral lock or .gear lock during or after assembly.The small locks and balls of the shift rod lock could fall out unnoticed. Shift into a gear in order to preventthe shift rods from being moved uninten1 = Shift collar 2 = Ball 3 = Driver dog 4 = Spring A = Recognitiongroove B = Dotting mark C = 2nd gear side D = 1 st gear side
34 35 37 Printed
321_99
tionally.
Disassembling and assembling transmission
in Germany
-29,
1999
GT334217
34 -223
www.WorkshopManuals.co.uk 911 Carrera (996)
34 55 37
Manual transmission
-Actuation,
ass. housing
Disassembling and assembling front transmission cover -GT3
2
I
173_99
34 55 37
Disassembling
Printed in Germany
-29,
1999
and assembling
front transmission GT334225
cover -GT3
34 -225
www.WorkshopManuals.co.uk Manual transmission
-Actuation,
ass. housing
911 Carrera (996)
Note: No. Designation
Qty.
Removal
Installation
1
Tightento 25 Nm (19 ftlb.)
1
Small collar faces bearing segmentNo.2
1
Hexagon-head bolt
2
Bearingsegment
3
Reverseidlergear
4
Needle cage
5
Pin
6
Snap ring
1
Bearing outer race
1
Heattransmissioncover to approx. 120°C
Heattransmissioncover to approx. 120°C. Drive in with an aluminiumor copper rod after heat exchange
8
Snap ring
9
Cylindrical-rollerbearing
10 1
12
1
Same as No.7
Same as No,
Oil guide lid Reversinglight switch
1
Transmission cover
1
34 -226
34 55 37
Tightento 15 Nm (11.0 ftlb.)
Disassembling
and assembling
GT334225
front transmission
cover -GT3
Printed in Germany
-29,
1999
www.WorkshopManuals.co.uk 911 Carrera
(996)
34 52 37
Manual transmission
Disassembling
-Actuation,
and assembling
ass. housing
gear housing -GT3
Tools
309_99
Item
Designation
Special tool
A
Striker
VW771
B
Mandrel
P 254
c
Pressure piece
P 254 a
D
Pressure piece
P 254 b
E
Threadedpiece
VW771/15
F
Pressurepiece
9649/1
G
Protectivesleeve
9649
H
Pressurepiece
9648/2
Pressurepiece
9648/1
Pressurepiece
9648
J
34 52 37 Printed
Disassembling
in Germany
-29,
1999
and assembling
Explanation
gear housing -GT3 GT334227
34 -227
www.WorkshopManuals.co.uk Manual transmission
-Actuation,
ass. housing
911 Carrera
(996)
Disassembling and assembling gear housing
190_99
34 -228
34 52 37
Disassembling GT334227
and assembling
gear housing -GT3
Printed in Germany
-29,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Manual transmission -Actuation, ass. housing
Note:
No. Designation
Removal
Qty.
1
Screw plug
1
2
Snapring
1
3
Bearing outer race
1
Installation Tighten to 30 Nm (22 ftlb.)
Drive out from the inside using special tools P 254 and P 254 b
4
Snapring
1
5
Snapring
1
6
Bearing outer race
1
Drive out from the inside using special tools P 254
Drive in with special tools P 254 and P 254 b
Drive in with special tools P 254 and P 254 a
and P 254 a Snap ring
8
1
Ballsleeve
Removewith special tools VW 771,
with special tool 9648
VW 771/15
(installation depth 14 mm)
and internal
Drive into correct position
(e.g. Messrs. Schrem
14-20) 9
Ball sleeve
1
10
Ball sleeve
1
Same as No.8
Same as No.8 (installation depth 0.6 mm)
11
Ball sleeve
1
Same as No.8
Same as No.8 (installation depth 14 mm)
12
Screw plug
1
Tighten to 20 Nm (15 ftlb.)
13
Compression spring
14
Locking pin
15
Circlip
1
Ensure perfect seating
16
Shift lever
1
Use protective sleeve (specialtool 9646)
34 52 37 Printed
Disassembling
in Germany -29,
1999
and assembling
Same as No.8 (installation depth 0.6 mm)
gear housing -GT3 GT334227
34 -229
www.WorkshopManuals.co.uk Manual transmission
-Actuation,
ass. housing
911 Carrera (996)
Note: No. Designation
Qty.
17
Shift catch
1
18
Roller
1
Removal
Installation
"Glue"on with viscous
grease
19
Shaftseal
1
20
Bearing sleeve
2
21
Rubberwasher
1
22
Gearhousing
1
Fill the space between the dust and sealing lips with grease (e.g. Liqui Moly). Drive in with special tool 9649/1 Drive out with specialtool
Drive into correct position
9684/2
with special tool 9684/1
www.WorkshopManuals.co.uk 911 Carrera
Manual transmission
(996)
34 37 37
-Actuation,
ass. housing
Disassembling and assembling transmission housing -GT3
Tools
G:>:~\
A eI[~~1
c
B
~ F
D [!)
c;;;;:)
G
~~
=
f[l
B
()
'\J
'W
0
p
Q
L M
N
310_99
Designation
Special tool
A
Striker
WJ 771
B
Protectivesleeve
9649
c
Pressurepiece
9648/2
D
Threadedpiece
VW 771/15
E
Pressurepiece
P 254 b
F
Pressurepiece
3062
G
Pressurepiece
9247/4
H
Pressurepiece
9252
Pressurepiece
WI 513
Item
34 37 37 Printed
Disassembling
in Germany
-29,
1999
and assembling
transmission GT334231
Explanation
housing -GT3
34 -231
www.WorkshopManuals.co.uk Manual transmission -Actuation, ass. housing
911 Carrera (996)
L
M
K
0
N
0 31O_99
Item
Designation
Special tool
Pressurepiece K
Socket wrench insert
9649/1 9658
L
Pull-intool and extractor
P 254
M
Mandrel
9515
N
Mandrel
VW295
0
Pressurepiece
P 264 b
p
Pressurepiece
9648/1
Q
Pressure piece
9648
34 -232
34 37 37
Disassembling GT334231
Explanation
and assembling
transmission Printed
housing -GT3
in Germany
-29,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Manual transmission -Actuation, ass. housing
Disassembling and assembling transmission housing
192_99
34 37 37 Printed
Disassembling
in Germany
-29,
1999
and assembling transmission GT334231
housing -GT3
34 -233
www.WorkshopManuals.co.uk Manual transmission -Actuation, ass. housing
911 Carrera (996)
Note: No. Designation 1
Qty.
Screw plug (with sealing
Removal
Installation
1
Clean,tighten to 30 Nm (22 ftlb.), Replacethe
ring)
sealing ring
2
Oval-headscrew
2
3
Guidetube
1
4
Shaft seal
1
5
Closure cap
1
6
Bushing
1
7
Shaftseal
1
Tightento 10 Nm (7.5 ftJb.)
Install only after fitting the gear set (also see Servo No. 35 50 19)
Drive out from the inside with special tool 9515
Do not grease, oil or clean with solvent(e.g. solventnaphtha).Drive in up to the stop with specialtool 9515 Drive in with special tool 9252 as far as the mountingface. Fill the space betweenthe dust and sealing lips with grease (e.g. Liqui Moly)
8
Ball sleeve
4
Removewith special tools VW 771, VW 771/15 and suitable internal puller (e.g. Messrs. Schrem 14-20)
Drive in with special tool 9648 (installation depth 0.6 mm)
9
Bearing outer race
1
Drive out with aluminiumor
Drive in as far as the stop with special tools 3062 and VW 295
copper mandrel,changing sides
10
1
Bearingouterrace
34 -234
34 37 37
Drive out from the inside with special tool VW 513
Disassembling GT334231
and assembling
Drive in with special tool 9247/4 and mandrel of specialtool P 254
transmission
housing -GT3
Printed in Germany
-29,
1999
www.WorkshopManuals.co.uk 911 Carrera (996)
Manual transmission -Actuation, ass. housing
Note: No. Designation 1
12
Qty.
Bearingouter race
1
Circlip
1
Removal
Installation
Drive out from the inside with specialtool P 264 b
Drive in with special tool P 254 b and mandrel of special tool P 254 Fit in correct position and make sure it is seated properly
13
Selector lever
1
14
Rubberwasher
1
15
Selectorlever
16
Shaft seal
1
17
Bushing
2
Use special tool 9649. Insert in correct position
Fill the space between the dust and sealing lips with grease (e.g. Liqui Moly). Drive in with special tool 9649/1 Drive out with specialtool
9684/2 18
Shift pinion
1
19
Adjustingshim
x
20
Snap ring
1
21
Closurecap
22
Compressionspring
34 37 37 Printed
Disassembling
in Germany
-29,
1999
Drive in with special tool 9684/1 End clearance 0...0.15 mm. Adjust with washer (No. 19)
Mark for refitting
Remeasureif necessary Use special tool P 375 to push the snap ring and closure cap (No 21) down until the snap ring engagesin its groove.
1
and assembling
transmission GT334231
housing -GT3
34 -235
www.WorkshopManuals.co.uk
Note:
No. Designation 23
Bearing screw*
Qty. 1
Removal
Installation
Remove with special tool
9658.
Tightento 50 Nm (37 ftlb.)
Unscrew it only if the transmission
has to be
disassembled!
24
Swivel arm
1
25
Transmission housing
1
&
*Caution! Parts of the shifting mechanism No. 23 is unscrewed.
will fall into the transmission
if the bearing
> Unscrewthe bearing screw only if the transmissionhas to be disassembled.
screw
www.WorkshopManuals.co.uk Manual transmission -Actuation, ass. housing
911 Carrera (996)
Disassembly and assembly instructions Disassembly
Assembly
1. Removeclosure cap. To do this, drill a 3.5 mm hole into the centre of the cap, screw in a sheetmetalscrew (4.8 x 25) with large washer, and lever the cap out using two screwdrivers.
1. Fit selector lever and shift pinion in the correct position. (The driver cross is vertical and the selector lever reachesthe flat surface of the housing.
400_99 484_98
2. Fit the retainer in the correct position and make sure it is seated properly.
A -Retainer
34 37 37
Disassembling
Printed in Germany
-29,
1999
and assembling
transmission GT334231
housing -GT3
308_99
34 -237
www.WorkshopManuals.co.uk
Removing and installing sealing ring for input shaft -GT3
35 50 19 Tools
3 091_99
Designation
Special tool
1
Pressure piece
9256
2
Sleeve
9255
3
Puller
9251
Item
35 50 19 Printed
Removing
in Germany
-25,
and installing
1999
Explanation
sealing ring for input shaft -GT3 GT335201
35 -201
www.WorkshopManuals.co.uk 35
Manual transmission
-Gears,
shafts, into gearsh.
911 Carrera (996)
Removing and installing sealing ring for input shaft Removal 1. Removeengine-transmissionunit and remove the transmission.
4. Pull out sealing ring by screwing in the hexagon-headscrew.
2. Removeguidetube for releasebearing. 3. Screw special tool 9251 securely into the sealingring.
093_99
Note
092_99
35 -202
35 50 19
The coil spring must be pulled off the input shaft with a wire hook if the spring shouldjump down when removingthe sealing ring.
Removing and installing GT335201
sealing ring for input shaft -GT3 Printed in Germany
-25,
1999
--{ ~
www.WorkshopManuals.co.uk 911 Carrera (996)
Manual transmission.
Gears, shafts, into gearsh.
Installation 1. Push assemblysleeve 9255 onto the toothing of the input shaft.
3. Drive in sealing ring with special tool 9256 as far as the mountingface.
--
I
) /
/ ,.i._~~~~:~Jt:::~..,; /'
'-~\
~~:==:=:::;~ \~;~::~~...; 095_99
094_99
2. Fill the space between the dust and sealing lips on the sealing ring with grease
4. Installthe guide tube and tighten the fastening screws to 10 Nm (7.5 ftlb.).
(e.g. Liqui -Moly).
35 50 19 Printed
Removing
in Germany
-25,
and installing
1999
sealing ring for input shaft -GT3 GT335201
35 -203
www.WorkshopManuals.co.uk 911 Carrera (996)
35 40 37
Manual transmission
Disassembling
-Gears,
and assembling
shafts, into gearsh.
input shaft -GT3
Tools
252_99
Item
Designation
Special tool
A
Insert
9282
B
Ringwrench insert, aff 41
35 40 37
Disassembling
Printed in Germany
-29,
1999
Explanation
Commerciallyavailable (refer to TechnicalEquipment Manual,Chapter 2.4, No. 96-2)
and assembling
input shaft -GT3 GT335205
35 -205
1 ~
www.WorkshopManuals.co.uk Manual transmission
-Gears,
shafts, into gearsh.
911 Carrera (996)
Disassembling and assembling input shaft
1
187_99
35 -206
35 40 37
Disassembling
GT335205
and assembling Printed
input shaft -GT3 in Germany
-29,
1999
1
www.WorkshopManuals.co.uk 911 Carrera (996)
Manual transmission
No. Designation
Qty.
-Gears,
shafts, into gearsh.
Removai
Note:
installation
1
Hexagonnut (self-locking)
1
Undowith special tool 9282 and ring wrench insert (aft 41)
Alwaysreplace. Tightento 250 Nm (185 ftlb.)
2
Cylindrical-rollerbearing
1
Using a suitable separator (e.g. Kukko 17-1), press it off via the 3rd gear gearwheel
Heatto approx. 120°C
3
Bearing inner race
1
4
Four-point bearing
1
5
Tensioningplate
1
Put on with lock No.8
6
Bearinginnerrace
1
Heatto approx. 120°C
7
Shift rod/shift fork (3rd and 4th gears)
8
Locking element
9
Thrust plate
1
Large flat-groundside faces the needle-roller
Heatto approx. 120°C
assembly
10
Loose gearwheel(4th gear)
1
11
Synchronisingring
1
12
Needle-roller assembly
13
Inner race
1
14
Guidesleeve
1
Replaceonly in pairs Mark for refitting
Check for wear; fit in the correct position with the same gear wheel (nubs facing the driver dogs)
Mark for refitting
Fit with the same gear wheel Heatto approx. 120°C
Removewith shift collar
Put on together with shift collar and synchronising components
35 40 37 Printed
Disassembling
in Germany
-29,
1999
and assembling
input shaft -GT3 GT335205
35 -207
www.WorkshopManuals.co.uk
Note:
No. Designation
15
Shift collar (with asymmetri-
Qty. 1
cally pointed teeth)
Removal
Installation
Synchronisingcomponents could pop out
Dotting marks centred with respect to the driver
dogs. Recognitiongroove must face to the loose gearwheel for 3rd gear. Put on together with guide sleeve
16
Driver dogs
3
17
Ball
3
18
Spring
3
19
Synchronising ring
1
Insert in correct position; curved side faces the shift collar
Mark for refitting
Checkfor wear; fit in the correct position with the same gear wheel (nubs facing the driver dogs)
20
Loose gearwheel(3rd gear)
1
21
Needle-rollerassembly
1
22
Input shaft
35 -208
Replaceonly in pairs Mark for refitting
35 40 37
Disassembling
GT335205
Fit with the same gear wheel
and assembling Printed
input shaft -GT3 in Germany
-29,
1999
www.WorkshopManuals.co.uk
911 Carrera (996)
Manual transmission
-Gears,
35
shafts, into gearsh.
Disassembly and assembly instructions Disassembly
Assembly
1. Clamp retaining device 9282 in a vice, push the input shaft on it and undo the hexagon nut using a commerciallyavailablering wrench insert (see Workshop EquipmentManual, Chapter2.4, No. 92-2).
1. Check synchronisingrings by pushingthem onto the gear wheels and measuringthe gap "A" with a feeler gauge. Installation dimension (new) Wear limit
= min. 0.9 mm = 0.6...0.7 mm
253_99 323_99
2. Using a suitable separator (e.g. Kukko 17-1), press all parts off the input shaft via the 3rd
2. Marking of the shift collar.
gear gearwheel
A -Recognition groove faces the loose gear wheel for 3rd gear B -Dotting marks centred with respect to the driver dogs
35 40 37
Disassembling
Printed in Germany
-29,
1999
and assembling
input shaft -GT3 GT335205
254_99
35 -209
www.WorkshopManuals.co.uk 911 Carrera (996)
35 59 19
Manual transmission
-Gears,
shafts, into gearsh.
Removing and installing pinion shaft -GT3
198_99
35 59 19
Removing and installing
Printed in Germany
-29,
1999
pinion shaft -GT3 GT335211
35 -211
www.WorkshopManuals.co.uk
Note:
No.
Designation
1
Pinionshaft
1
Observepairingnumber.
2
Fixed gearwheelfor 4th
1
Large flat-groundcollar faces the tensioning plate
Qty.
Removal
gear 3
Adjusting shim (S4)
x
Notethe quantityand thicknessfor reinstallation
4
Adjusting shim (55)
x
Note the quantityand thicknessfor reinstallation
5
Input shaft with tensioning
1
plate
Installation
1
www.WorkshopManuals.co.uk 911 Carrera
35 61 55
(996)
Manual transmission
-Gears,
shafts, into gearsh.
35
Replacing bearings for pinion shaft -GT3
Note: No. Designation
Removal
Qty.
Bearing inner race
1
Mark for refitting, press off with a suitable separator (e.g. Kukko 15 -17).
Installation Do not confuse with inner race No.3. Heat to approx. 120 °C and
presson ?
Four-pointbearing
3
Bearing inner race
1
Mark for refitting, press off with a suitable separator (e.g. Kukko 15 -17).
Do not confuse with inner race No.1.
Heat
to approx. 120 °C and
press on 4
5
Cylindrical-rollerbearing
Replacing
Printed in Germany -29,
Press off with a suitableseparator (e.g. Kukko 15 -17)
1
Pinionshaft
35 61 55
1
position
Observepairing number Readjustif necessary
bearings for pinion shaft -GT3
1999
Heat to approx. 120 °C and press on in correct
GT335213
35 -213
www.WorkshopManuals.co.uk 911 Carrera (996)
39 40 37
Final drive -Differential,
Disassembling
and assembling
differential
GKN differential
lock
lock -GT3
Tools
A
c
B ~~1
96_99
Item
Special tool
Designation
A Connectingpiece
Shop-made (flat steel 6 x 18)
B Pressure piece
P263
c
P264b
Pressure piece
9646
E Clampingjaws
39 40 37 Printed
Disassembling
in Germany
-25,
Explanation
1999
and assembling
GKN differential GT339201
lock -GT3
39 -201
~ rl1 "" ~
www.WorkshopManuals.co.uk
Disassembling and assembling GKN differential lock
3
4 6
7
e e
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if
10 11 12 11 12
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16
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14 ~I 16
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14
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