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Home >> Porsche >> 2011 >> 911 Speedster >> Repair and Diagnosis >> Drivelines & Axles >> Driveshaft & Universal Joints >> 39 - Final Drive - Differential, Differential Lock -- CARRERA (997) >> WM 394037 Disassembling And Assembling Differential With Differential Lock (Gt2, Gt2 RS, Gt3 & Gt3 RS) >> Assembling Differential With Differential Lock >> Assembling Differential And Differential Lock

Assembling Differential And Differential Lock

Fig 1: Identifying Differential Components
G09825329Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Taper roller bearing (large)
  2. Adjusting shim
  3. Taper roller bearing (small)
  4. Adjusting shim
  5. Screw
  6. Crown wheel
  7. Countersunk-head screw
  8. Lids
  9. Thrust washer
  10. Cup spring
  11. Outer disc
  12. Inner disc
  13. Thrust ring (outside)
  14. Shaft bevel gear with threaded washer
  15. Bevel pinion
  16. Axle
  17. Thrust ring (inside)
  18. Housing
  1. Assemble differential.

    Information 

    • Always replace the complete disc pack in the case of repairs. 
    • Replacing individual discs is not permissible. 
    1. Cup spring
    2. Outer disc
    3. Inner disc
    4. Thrust washer

    Lightly lubricate all friction surfaces on discs, thrust rings and axles with transmission oil.

    Install cup springs so that the cambers face inwards towards the disc pack.

    Fig 2: Identifying Differential Discs
    G09825330Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Measuring basic locking torque.
    1. Shop-made connecting piece (flat steel 6 x 18 mm)
      Fig 3: Identifying Shop-Made Connecting Piece Dimensions
      G09825331Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    After assembling, measure the basic locking torque with a stationary and a driven shaft bevel gear. To do this, clamp one flange in the vice with two screws and position differential. Insert second flange with Shop-Made Connecting Piece -A-  and turn differential with a torque wrench. A basic locking torque of → Torque: 5 Nm (3.5 ft. lb.)+10 Nm (+7.5 ft. lb.)  must be reached.

    1. Shop-made connection piece (flat steel 6 x 18 mm)
      Fig 4: Turning Differential
      G09825332Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Install differential cover.

    Stick thrust washer -9-  using viscous grease onto differential cover.

    Position cover onto marked installation position and tighten screws -7-  .

    → Tightening torque: 15 Nm (11 ft. lb.) 

  4. Install crown wheel with cover.

    The screws -5-  for the crown wheel must -6-  always be replaced  and tightened → Tightening torque: 200 Nm (150 ft. lb.). 

  5. Press in taper roller bearing.

    If the taper roller bearings with outer bearing shells are to be replaced, the differential must be measured (total disc thickness S1 and S2) and, where applicable, adjusted, see:

    → 390815 ADJUST RING GEAR AND PINION SHAFT  - chapter on "Adjusting"

    1. 5.1. Press in taper roller bearing (large) -1-  .
      Fig 5: Installing Taper Roller Bearing (Large) Crown Wheel
      G09825333Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 5.2. Press in taper roller bearing (small) -3-  .
      Fig 6: Installing Taper Roller Bearing On Crown Wheel
      G09825334Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Install outer bearing ring.
    1. 6.1. Install left outer bearing ring (large).

      Heat cover up to approx. → Temperature: 120°C (248 °F)  . Following an exchange of heat use drift Extractor Tool P254 

    2. 6.2. to install right outer bearing ring (small).

      Drive in outer bearing ring using Pressure Piece 3062  and Drive-In Mandrel VW 295  .

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