User manual PORSCHE 930 TURBO USA 1976 CURRENT FLOW DIAGRAM

[. . . ] case Vent M 14xl. 5 Gearshift rod Conical scr. M 8xl. 25 8. 8 X 12 Cr 23-26 (2. 3-2. 6) 22-25 Shift cover Mid-grip nut M 8xl. 25 No 18. 8 Gear housing (2. 2-2. 5) 25-35 (2. 5-3. 5) 9-11(0. 9-1. 1) Backup light M 18xl. 5 MS switch Gearshift forks Clamp, gears, transm. I Hex nut M 6xl. O 8. 8 8 Hex nut M 8xl. 25 22-25 case, front and side covers (2. 2-2. 5) Shift lock, transm. case Selector forks Ring gear, Hex hd screw M lOxl. 5 8. 8 8. 8 11. 9 15-18 (1. 5-1. 8) Hex hd screw M 8xl. 25 24-26 (2. 4-2. 6) 135-140 (13. 5-14) Hex hd screw M 12xl. 25 differential Hex hd screw M 12xl. 25 12. 9 5t 37-5. 8 150-160 (15-16) Transm. case oil drain Gear housing Oil filler Reverse gear Plug with M 24x1. 5 Con. 1:16 magnet Plug 20-25 (2-2. 5) 5. 8 5. 8 20-25 (2-2. 5) 20-25 (2-2. 5) Plug M 16xl. 5 Lock Printed in Germany -IV. I I 1981 Technical Data 30-03 Location Designation Threads Material Torque Nm (kpm) Guide tube Capscrew M 6xl. O 8. 8 8. 8 8 8-10 (0. 8-1. 0) 20-'-5 (2. 0-2. 5) 46-50 (4. 6-5. 0) Clutch and startergear Starter Capscrew Hex nut M 8xl. O M lOxl. 5 Mech. controls Holder to base Hex hd screw M6 8. 8 6 (0. 6) 21 Baseto tunnel Socket head capscrew M8 8. 8 (2. 1) M8 I Con. screw in shift rod end Con. [. . . ] Place reverse gear shaft or other corresponding shaft in bore of gear housing. Slide on reverse gear II as illustrated and place in 4th. 3. Pull off cylindrical rollex bearing toward front. 4. Remove all parts from drive pinion and drive shaft, and mark needle bearings for installation (also refer to 'Dismantling and Assembling Drive Pinion and Drive Shaft"). 2. Loosenclamp nuts andremovedrive pinion and drive shaft. Note Plug is under heavy spring tension. Prevent spring and plug from jumping away when unscrewing (danger of injuries). 6. Note numberand thickness for-installation. Printed in Germany Dismantling and Assembling Change Gear 35-5 Installing 1. Install shims in number and thickness as noted or as determined while adjusting the 5. Treat threads with Locquic Activator to assurea perfect lock. pinion. 6. Torquedrive shaftnut to specified data. 2 . Install preassembled drive pinion and drive shaft, and torque clamp nuts to specifi- cations. 7. Install drive pinion and drive shaft as follows. 4th speed gear II Needle cage. spacer, 4th speed gear I Operating sleeve for 3rd and 4th speed Gearshift sleeve; selector fork and selector rod for 3rd and 4th speed e. Let tered side faces in same direction as countergear Remove with 9108 Remove with 9108 Remove with Heat about 1200 C and drive on 4th speed gear II 15 16 17 Bearing inner race 1 4-point bearing 1 1 Bearing inner race 9108 Heat about 120 C and drive on 0 Printed in Germany -II, 1976 Disassembling and Ass. 'tmbling Drive Pinion 35-17 l~emoving IAmt. Mech. gear -shift system -gears, shafts DISA SSEMB LING AND A SSEMB LING IN STRUC TION S Disassembling Note The blow-up drawing showsthe entire drive pinion without clamping plate for better understanding. The parts up to and including number 14 are taken off and installed on an installed drive pinion (refer to 'Removing and Installing Change Gear"). Assembling 1. Heat cylindrical roller bearing to about 120oC and drive on. Note Install bearing so that the two-part roller cage with :installed race faces gear set. 1. Removecylindrical roller bearingand four point bearing with special tool number9108. Modification -1977 Model Asymmetricallyprofiled teeth of 1st/2nd gear operatingsleeve mustface toward 1stgear. 35-18 Disassembling and Assembling Drive Pinion II. 1976 -Printed in Germany TOOLS . Mech. gear -shift system -gears, shafts Designation 1 2 Amt. 1 1 Notes Removing Installing Remarks Seal Seal Lubricateslightly. Remove with screwdriver Drive in to stop with pressuresleeve. 3 Pipe 1 35-20 Removing and Installing Drive Shaft Seal Printed in Germany INo. REMOVING AND INSTALLING INSTRUCTIONS Removing 1. Unscrew guide sleevecapscrews remove and guide sleeve. Installing 1. Remove seal. Printed in Germany Removing and Installing Drive Shaft Seal 35-21 2. Install guide sleeve for release bearing and coat with MoS paste. 2 6. Bolt transmission to engine and install this assembly. 35-22 Removing and Installing Drive Shaft Seal Printed in Germany 7 No. 1 Designation Amt. ] Notes Removing Installing Install correctly. must fit properly. Remarks Snap ring Remove with small screwdriver 2 3 Lockwasher Synchronizer ring 1 1 Check for wear, install correctly. 4 5 6 Stop Lock 2 ] ] Install correctly Install. correctly stop Gear 1 Printed in Germany Dismantling and Assembling Synchronization 35-23 Mech. gear -shift system -gears. shafts 7 No. 1 Designation Amt. 1 Notes Removing Remar ks Installing Install correctly. [. . . ] Remove differential, pull off both tapered roller bearings and split up total shim thickness"5 . . as follows. Becaus~o~fbacklash adjustment later spacer 5 is selected 0, 20 mm thinner than spacer 51 2' Round off the spacer thicknesses to the available distance that the total shim thickness 81 and 82 is not changed. Example: Example: Total thickness of spacers5 + 5 = 6. 15 mm. Thickness of spacer 51: 1 2 Rounded off spacer thicknesses S +S = 2, 85 + 3, 30 = 6, 15 mm. 1 2 Measure thickness of shims at several points with a micrometer. permissible deviation 6, 15 mm 2 = 3, 075 mm -0. 20 mm 0. 02mm. Check shims for burrs and damage. 2, 875 mm 39 -16 Printed in Germany "5 ADJUSTING BACKLASH Backlash should be 0, 14 to 0, 20 mm. [. . . ]