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Home >> Porsche >> 2015 >> Macan Turbo >> Repair and Diagnosis >> External Pages >> Different car >> Section 168 (34 - Mechanical Gear-Shift System - Actuation, Housing -- CARRERA (997)) >> WM 343537 Disassembling And Assembling Transmission (Gt2, Gt2 RS, Gt3, Gt3 RS & Gt3 RS 4.0) >> Disassembling Middle Gear Wheel Set For 1st-4th Gear

Disassembling Middle Gear Wheel Set For 1st-4th Gear

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Fig 1: Overview Of Middle Gear Wheel Set
G09823772Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Cylindrical-roller bearing
  2. Thrust plate
  3. Loose gear wheel, 1st gear
  4. Friction ring
  5. Cone ring
  6. Synchronizer ring
  7. Needle-roller bearing
  8. Inner bearing ring
  9. Shift sleeve
  10. Guide sleeve
  11. Spring
  12. Ball
  13. Driver dog
  14. Synchronizer ring
  15. Cone ring
  16. Friction ring
  17. Loose gear wheel, 2nd gear
  18. Needle-roller bearing
  19. Inner bearing ring
  20. Thrust plate
  21. Fixed gear wheel, 3rd gear
  22. Oil pipe
  23. Locking element
  24. Shift rod (1st/2nd gear)
  25. Intermediate locking element
  26. Shift rod (reverse gear)
  27. Shifting shaft
  28. Shift rod (5th/6th gear)
  29. Tensioning plate
  30. Nut
  31. Shift rod (3rd/4th gear)
  32. Cylindrical-roller bearing
  33. Screw plug
  34. Spring
  35. Ball
  36. Adjusting shim S3
  37. Transmission housing
  38. Oil pump drive wheel
  39. Fixed gear wheel, 4th gear
  1. Remove oil pipe and screw plug.
    1. 1.1. Unscrew screw -A-  and remove oil pipe -B-  .
    2. 1.2. Unscrew screw plug -C-  and remove springs and balls.
    Fig 2: Identifying Oil Pipe
    G09823773Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Remove transmission housing.

    Unscrew screws and force transmission housing -37-  off using a rubber hammer.

  3. Remove screw plugs.

    Unscrew screw plugs -1-  and remove springs and balls.

    Fig 3: Identifying Screw Plugs
    G09823774Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Remove shift rod for reverse gear -26-  .
  5. Remove differential with differential lock.

    → 394019 REMOVING AND INSTALLING DIFFERENTIAL WITH DIFFERENTIAL LOCK - section on "Removing"

    Fig 4: Overview Of Differential Lock
    G09823775Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Pull off cylindrical-roller bearing on the input and output shafts.
    1. 6.1. Remove cylindrical-roller bearing -1-  from the drive shaft using Puller Hook Nr. 105  and Pressure Pieces 9656  .
      Fig 5: Removing Cylindrical-Roller Bearing From Drive Shaft Using Puller Hook Nr. 105 And Pressure Pieces 9656
      G09823776Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 6.2. Pull loose gear wheel for 1st gear -2-  with the thrust washer and cylindrical-roller bearing -1-  off the output shaft using Puller Hook Nr. 105 And Pressure Pieces 9656  .
      Fig 6: Loosing Gear Wheel For 1st Gear And Cylindrical-Roller Bearing On Output Shaft
      G09823777Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Remove gear wheel set for 1st-2nd gear.

    Information 

    When removing and installing gear wheel sets and shift rods, the small synchronization parts (balls, driver dogs, springs in the locking mechanism -2, 3, 4-  ) can pop out when you move them. We recommend the following approach:

    Make sure not to change the zero position of the shift sleeve -1-  during removal and insert the complete gear wheel set with loose gear wheels during installation.

    Fig 7: Identifying Synchronization
    G09823778Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 7.1. Fixed gear wheel for 3rd gear -1-  with gear wheel set for 1st-2nd gear Pull off gear using puller hook Nr. 105  and pressure pieces 9656  .
      Fig 8: Pulling Off Gear Using Puller Hook Nr. 105 And Pressure Pieces 9656
      G09823779Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Remove oil pump drive wheel.
  9. Remove fixed gear wheel for 4th gear.
  10. Remove oil pipe.

    Unscrew screws -1, 2-  and remove the oil pipe -3-  .

    Fig 9: Identifying Oil Pipe With Screws
    G09823780Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  11. Remove tensioning plate with the input and output shafts.

    Screw off nuts -1-  and pull tensioning plate with input and output shafts and remaining gear wheels out of the transmission housing.

    Fig 10: Identifying Tensioning Plate
    G09823781Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  12. Disassemble output shaft.
    Fig 11: Overview Of Output Shaft
    G09823782Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Adjusting shim S4
    2. Adjusting shim S5
    3. Inner bearing ring
    4. Four-point bearing
    5. Inner bearing ring
    6. Cylindrical-roller bearing
    7. Output shaft
    1. 12.1. Remove adjusting shims S4 and S5 -1, 2-  .

      Note the number and thickness for re-installation.

    2. 12.2. Press off cylindrical-roller bearing.

      Press off cylindrical-roller bearing -6-  with inner bearing rings -3, 5-  and four-point bearing -4-  .

      Fig 12: Pressing Off Cylindrical-Roller Bearing On Output Shaft
      G09823783Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  13. Disassemble drive shaft.
    Fig 13: Disassembled View Of Drive Shaft
    G09823784Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Nut (self-locking)
    2. Cylindrical-roller bearing
    3. Inner bearing ring
    4. Four-point bearing
    5. Tensioning plate
    6. Inner bearing ring
    7. Shift rod/shift fork for 3rd/4th gear
    8. Lock
    9. Thrust washer
    10. Loose gear wheel, 4th gear
    11. Synchronizer ring
    12. Needle-roller bearing
    13. Inner bearing ring
    14. Guide sleeve
    15. Shift sleeve
    16. Driver dog
    17. Ball
    18. Spring
    19. Synchronizer ring
    20. Loose gear wheel, 3rd gear
    21. Needle-roller bearing
    22. Drive shaft
    1. 13.1. Clamp the drive shaft in a vice.

      Clamp the complete drive shaft -22-  with the gear wheel set in a vice using special tool Socket-Wrench Insert 9282  .

      Fig 14: Clamping Complete Drive Shaft With Gear Wheel Set In Vice Using Special Tool
      G09823785Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 13.2. Remove (self-locking) nut -1-  .
    3. 13.3. Press off loose gear wheel for 3rd gear

      Press off loose gear wheel for 3rd gear -20-  with synchronization, loose gear wheel for 4th gear -10-  and the remaining parts.

      Fig 15: Pressing Off Drive Shaft
      G09823786Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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