User manual PORSCHE 944 WORKSHOP MANUAL 1991

[. . . ] 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 are not observed. if the 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 vorwort -1 page 1 www. WorkshopManuals. co. uk Foreword 911 Carrera (996) 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. [. . . ] Push bellowsforward until it engagesin the groove of the central shaft. Check whether the bellows is seated properly by pulling on it. Transmissionsupport; transmissioncarrier on transmission mount (M 10) = Transmissionsupport on body (MID) = 65 Nm (48 ftlb 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) Final drive -Differential, differential lock 39 82 19 Tools Removingand installing sealing ring for cardan flange 276_98 Item Designation Special tool Explanation commerciallyavailable (refer to Technical Equipment Manual, Chapter 2. 4, No. 64). wrenchinsert A Socket B Pressure piece puller C Three-arm 9639 Commercially available (refer to Technical Equipment Manual, Chapter 2. 4, No. 112-1) 39 82 19 Printed Removing and installing sealing ring for cardan flange -14, 1998 C4S39109 39 -109 in Germany www. WorkshopManuals. co. uk Final drive -Differential, differential lock 911 Carrera 4 (996) Removing and installing sealing ring for cardan flange Removal 1. Remove collar nutwith a long aff 30 socket wrenchinsert(referto Workshop Equipment Manual, Chapter 2. 4, No. / fflYA :. . :. ~ / 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 6. Screw in a large sheetmetal screw (4. 8 x 25) with a large washer and lever out the sealing ring with two screwdrivers. Installation 1. Degreasethe pinion shaft journal (splinesand thread), halfshaftflange splinesand thread of the collar nut with cleaning agent (e. g. Fill the space betweenthe dust and sealing lips on the sealing ring with grease (e. g. To do this, clamp the flange in the vice with protective jaws and press out the snap ring with the new snap ring "A", 39 -120 39 59 19 Removing and installing C4S39119 sealing ring for flanged shaft Printed in Gennany -14, 1998 ~ www. WorkshopManuals. co. uk www. WorkshopManuals. co. uk Final drive -Differential, differential lock 911 Carrera 4 (996) Removingand installing cover for final drive Removal Installation Install in reverse order I observing the following points: 1. Unscrewfastening screws for the lid and remove the lid by tapping it with a plastic hammer. 1. Fit lid carefullyand tighten screws uniformly in diagonallyopposite sequence. Use special tool 9321 to aid assembly. A -Centring pins 9321 260_98 . 8 39 -122 39 58 19 C4S39121 Removing and installing cover for final drive Printed in Gennany -14, 1998 www. WorkshopManuals. co. uk 911 Carrera 4 (996) Final drive -Differential, differential lock 3. To do this, clamp the flange in the vice with protective jaws and press out the snap ring with the new snap ring "A". -- '\ A -New snap ring 175_97 4. Grease snapring well anddrivein the the halfshaft flangeusingthe special tools P254 and9247/1. Tightening torques: Oil drain plug on final drive (M18 x 1. 5) Lid on final drive (M8) 28 Nm (21 ftlb. = 25 Nm (19 ftlb. ) . 39 58 19 Removing and installing cover for final drive C4S39121 39 -123 Printed in Germany -14, 1998 www. WorkshopManuals. co. uk 911 Carrera 4 (996) Manual transmission -Actuation, housing 39 90 55 Changing oil for final drive Filling capacity: approx. Unscrewthe oil filler screw and drain plug and drain the oil with the vehicle horizontal. 1~~~\ \=\ ~ 262_98 B -Drain plug 3. Tightenthe drain plug and filler screw with 28 Nm (21 ftlb. ). A -Oil filler screw 246_98 39 90 55 Changing oil for final drive C4S39125 39 -125 Printed in Germany -14, 1998 www. WorkshopManuals. co. uk 911 Carrera 4 (996) Final drive -Differential, differential lock 39 62 19 Removing and installing support for final drive 482_98 A -Support for final drive B -Fastening screws 39 62 19 Printed Removing and installing support for final drive -18, 1998 C4s39127 39 -127 in Germany www. WorkshopManuals. co. uk Removing and installing support for final drive Removal 1. Fitsupportin the correctposition (angled sidefacingupwards). A -Tabs 2. Tightenfastening screws in two stages. 48O_98 1st stage: Screw both screws to 5 Nm (3. 7 ftlb. ). 2nd stage: Tighten both screws to 65 Nm (48 ftlb. ). [. . . ] Securethe universaldial gauge holder VW 387 with dial gauge and extensionon the housingand set it to "0" with 2 mm preload. Adjusting crown wheel Determinethe total disc thickness "$ tot. " ($1 + $2). Readjustment the crown wheel is necessaryif: of the transmission housing, side transmission cover, taper roller bearingsfor the differential, differential housingor gear set is replaced. Note The pinion shaft must be removed in order to determinethe preload of the tapered roller bearingson the differential. Make sure that the bearing outer races of the tapered roller bearingsare firmly seated in the transmissionhousingor in the side transmission cover. Fit one 2. 5 mm thick spacer ring each on the crown wheel side and the opposite side of the differentialto be used. [. . . ]