LEMON Manuals: Even more car manuals for everyone
Home >> Porsche >> 2003 >> 911 Carrera 4S, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 6 (Manual Transmission, Controls, Case) >> Disassembling And Assembling Transmission Case Cover (Transmission G 86) >> Tools

Disassembling And Assembling Transmission Case Cover (Transmission G 86): Tools

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2004 Porsche Boxster, 2003 Porsche Boxster, 2002 Porsche Boxster, 2001 Porsche Boxster, and 2000 Porsche Boxster. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tools - Disassembling And Assembling Transmission Case Cover
G03102667Courtesy of PORSCHE OF NORTH AMERICA, INC.
SPECIAL TOOLS - DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER

No. Designation Special tool Explanation
1(1) Striking tool VW 771  
2(1) Threaded piece VW 771/15  
3(1) Pressure piece 9247/1  
4(1) Pressure piece VW 295 a  
5(1) Pressure piece 3005  
6(1) Pull-in tool and extractor P 254  
7(1) Threaded adapter (M10/M8) - Standard (e.g. Messrs. Kukko 18 - 008 A)
(1) For explanation see Fig 1
Fig 2: Exploded View Of Case Cover (Transmission G 86) Components
G03102668Courtesy of PORSCHE OF NORTH AMERICA, INC.
CASE COVER (TRANSMISSION G 86)

No. Designation Qty. Removal Installation
1(1) Oil collecting vessel 1   Push in until the lock engages in the transmission case cover hole. The collecting vessel must face upwards.
2(1) Snap ring 1    
3(1) Washer 1    
4(1) Reverse idler gear 1    
5(1) Needle roller bearing 2    
6(1) Thrust washer 1    
7(1) Retaining sleeve 1 Force out with a suitable internal puller and special tool VW 771 Do not reinstall (required only during manufacture in Production)
8(1) Tapered roller bearing outer race 1 Remove with the special tools VW 771, VW 771/15 and standard threaded adapter Press in with the special tool 3005 and a suitable plunger (e.g. special tool VW 407)
9(1) Adjusting shim "S4" X Note the thickness for refitting Measure again if necessary (2)
10(1) Pressure plate 1    
11(1) Rubber disc 1 If necessary, drill a hole in the disc and pull out with a sheetmetal screw Replace if necessary
12(1) Needle roller bearing 1 Remove with the special tools VW 771, VW 771/15 and a suitable internal puller (e.g. Kukko 21/4, 22 - 28 mm). Destroy the plastic sleeve No. 13 before fitting the puller. Always replace. Press in the correct position using the special tool VW 295 a and a suitable tubular piece (e.g. special tool VW 420). The large collar of the special tool VW 295 a faces the needle roller bearing
13(1) Plastic sleeve 1 Is destroyed during removal Always replace
14(1) Bushing 1 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
15(1) Shaft seal 1 Lever out Fill the chamber between the dust lip and sealing lip with multipurpose grease and drive in with a suitable tubular piece (e.g. special tool VW 423)
16(1) Torx screw 1 Must be removed only if the reverse idler shaft is replaced Tightening torque 35 Nm (26 ft.lb)
17(1) Transmission case cover 1   If the cover is replaced, remeasure the adjusting shim "S4".(2) Seal with Loctite 573.
(1) For explanation see Fig 2 .
(2) For adjustment, see ADJUSTMENT OVERVIEW (TRANSMISSION G 86) and DETERMINING "S4" AGAIN (TRANSMISSION G 86) .
scientia non olet · About LEMON Manuals