Disassembling And Assembling The Transmission Housing (Transmission G 86): Tools

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Fig 1: Identifying Special Tools - Disassembling And Assembling The Transmission Housing

Courtesy of PORSCHE OF NORTH AMERICA, INC.

SPECIAL TOOLS - DISASSEMBLING AND ASSEMBLING THE TRANSMISSION HOUSING

No.

Designation

Special tool

1⁽¹⁾

Striking tool

VW 771

2⁽¹⁾

Bridge

VW 771/29

3⁽¹⁾

Pull-in tool and extractor

P 254

4⁽¹⁾

Drive-in mandrel

VW 295

5⁽¹⁾

Hook

VW 681

6⁽¹⁾

Pressure piece

9247/4

7⁽¹⁾

Pressure piece

3128

8⁽¹⁾

Pressure disc

VW 511

9⁽¹⁾

Pressure piece

30 - 205

10⁽¹⁾

Pressure piece

40 - 202

11⁽¹⁾

Pressure piece

9247/1

12⁽¹⁾

Drive-in mandrel

VW 195

13⁽¹⁾

Threaded piece

VW 771/15

⁽¹⁾	For explanation see Fig 1 .

Fig 2: Exploded View Of Transmission Housing (Transmission G 86)

Courtesy of PORSCHE OF NORTH AMERICA, INC.

TRANSMISSION HOUSING (TRANSMISSION G 86)

Note:

No.

Designation

Qty.

Removal

Installation

1⁽²⁾

Oil drain plug

See CHANGING AND CHECKING TRANSMISSION OIL (TRANSMISSION G 86) .

Tightening torque 25 Nm (18 ft.lb)

2⁽²⁾

Torx screw

Tightening torque 10 Nm (7 ft.lb)

3⁽²⁾

Torx screw

Tightening torque 25 Nm (18 ft.lb)

4⁽²⁾

Tab washer

5⁽²⁾

Reversing light switch

6⁽²⁾

Toroidal sealing ring

Always replace, lightly oil

7⁽²⁾

Cap

8⁽²⁾

Tapered roller bearing outer race⁽¹⁾

Pull out with special tools 3128 and VW 771/29

Press in with a suitable pressure piece

9⁽²⁾

Adjusting shim "S3"

Note the thickness for reinstallation

Remeasure if necessary.⁽³⁾

10⁽²⁾

Needle roller bearing

Press out with special tools VW 295 and 40 - 202

Press in the correct position with the special tools VW 40 - 202 and VW 295 (do not strike).
When doing so, the labelled side (greater sheet thickness) faces the pressure piece

11⁽²⁾

Bushing

Remove with the special tools VW 771, VW 771/15 and a suitable internal puller (e.g. Kukko 21/4, 23.5...30 mm)

Press in with the special tools 9247/1 and P 254

12⁽²⁾

Torx screw

Tightening torque 20 Nm (15 ft.lb)

13⁽²⁾

Cover

Remove with the special tools VW 771, VW 771/15 and a suitable internal puller (e.g. Kukko 21/3, 18.5...23.5 mm)

14⁽²⁾

Torx screw

Tightening torque 10 Nm (7 ft.lb)

15⁽²⁾

Lock (5th and reverse gear)

16⁽²⁾

Toroidal sealing ring

Always replace, lightly oil

17⁽²⁾

Shaft seal

Pull out with the special tool VW 681 (also possible with transmission installed)

Fill the chamber between the dust lip and sealing lip with multipurpose grease. Drive in the correct position using the special tool VW 195 (5.5 mm under the upper edge of the cover)

18⁽²⁾

Tapered roller bearing outer race (small) *

Drive out with a suitable aluminum or copper mandrel (phi 6...8 mm)

Press in with the special tools 30 - 205 and VW 295

19⁽²⁾

Adjusting shim "S2"

Note the thickness for reinstallation

Remeasure the thickness if necessary

20⁽²⁾

Adapter

21⁽²⁾

Ball journal

Tightening torque 25 Nm (18 ft.lb)

22⁽²⁾

Sleeve

Press in the correct position

23⁽²⁾

Transmission housing⁽¹⁾

24⁽²⁾

Oil filler screw

Tightening torque 25 Nm (18 ft.lb)

25⁽²⁾

Shaft seal

Same as No. 17

same as No. 17

26⁽²⁾

Tapered roller bearing outer race (large)⁽¹⁾

Same as No. 18

Press in with the special tools VW 511 and VW 295

27⁽²⁾

Adjusting shim "S1"

Same as No. 19

28⁽²⁾

Cover for final drive⁽¹⁾

Seal with Loctite 573

⁽¹⁾	If these parts are replaced, readjustment is necessary. See ADJUSTING THE DRIVE SET (TRANSMISSION G 86) .

⁽²⁾	For explanation see Fig 2 .

⁽³⁾	See APPROPRIATE SEQUENCE FOR READJUSTING THE DRIVE SET (TRANSMISSION G 86) .