Disassembling Front Gear Wheel Set For 5th-6th Gear

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Fig 1: Overview Of Gear Wheel Sets For 5th-6th Gear

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Nut (self-locking)
Cylindrical-roller bearing
Thrust plate
Loose gear wheel, reverse gear
Synchronizer ring
Needle-roller bearing
Inner bearing ring
Shift sleeve
Washer
Screw
Shift fork (reverse gear)

15 - Guide sleeve with snap ring
16 - Loose gear wheel, 5th gear
17 - Synchronizer ring
18 - Needle-roller bearing
19 - Inner bearing ring
20 - Shift sleeve
21 - Driver dog
22 - Ball
23 - Spring
24 - Guide sleeve
25 - Shift fork (5th and 6th gear)
26 - Synchronizer ring
27 - Loose gear wheel, 6th gear
28 - Needle-roller bearing
29 - Inner bearing ring
30 - Thrust plate
31 - Nut (self-locking)
32 - Inner bearing ring
33 - Fixed gear wheel, reverse gear
34 - Spacer sleeve
35 - Fixed gear wheel, 5th gear
36 - Spacer sleeve
37 - Fixed gear wheel, 6th gear
38 - Housing

Unscrew nuts on the drive and output shafts.
Information

The transmission must be supported at the drive and output shafts when loosening and tightening nuts.
1. 1.1. Block the drive shaft.
  Fit special tool Retaining Device 9253 on the drive shaft and secure to the transmission bell housing with two screws.
  
  Fig 2: Blocking Drive Shaft
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Information
  
  The transmission must be supported at the drive and output shafts when loosening and tightening nuts.
2. 1.2. Unscrew nuts on the drive and output shafts -1, 2- .
  
  Fig 3: Identifying Nuts On Drive And Output Shafts
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Loosen shift forks.
Remove clamping screw -A- from the shift forks.

Fig 4: Identifying Shift Fork In Front Gear Wheel Set
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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 5: Identifying Synchronization Components
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove reverse gear.
1. 3.1. Remove fixed gear wheel for reverse gear -1- .
  Remove fixed gear wheel for reverse gear -1- from the drive shaft using a Two-Arm Extractor Nr. 101 and special tool Pressure Piece 9656 . Pull off inner bearing ring at the same time.
  
  Fig 6: Removing Fixed Gear Wheel For Reverse Gear
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Remove loose gear wheel for reverse gear -2- .
  Remove loose gear wheel for reverse gear -2- and needle-roller bearing from the output shaft using a Two-Arm Extractor Nr. 101 and special tool Pressure Pieces 9656 . Remove cylindrical-roller bearing -1- and thrust plate at the same time.
  
  Fig 7: Removing Loose Gear Wheel For Reverse Gear
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove spacer sleeve on drive shaft.
Pull off inner bearing ring (output shaft).
1. 5.1. Press complete gear wheel set -1- forward by 1 - 2 cm on the output shaft using two mounting levers.
  
  Fig 8: Pressing Gear Wheel Set Forward
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 5.2. Pull off inner bearing ring.
  Push back gear wheel set behind inner bearing ring -2- and remove inner bearing ring -2- using a two-arm extractor Nr. 101 and special tool Pressure Pieces 9656 .
  
  Fig 9: Pulling Off Inner Bearing Ring (Gear Wheel Set)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove gear wheel set for reverse 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 10: Identifying Synchronization Parts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Open up shift fork -11- and remove complete synchronization.
Remove gear wheel set for 5th-6th 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 11: Identifying Synchronization Components
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 7.1. Remove gear wheel set for 5th-6th gear.
  Open up shift fork -5- and remove complete synchronization.
  
  Fig 12: Removing Front Gear Wheel Set For 5th Gear
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 7.2. Remove fixed gear wheel for 5th gear -1- and spacer sleeve -2- .
3. 7.3. Remove loose gear wheel for 5th gear -3- .
4. 7.4. Pull off inner bearing ring -19- (output shaft).
  Pull off inner bearing ring -19- using extractor and special tool Pressure Pieces 9656 .
5. 7.5. Open up shift fork -6- and remove complete synchronization.
  Remove loose gear wheel for 6th gear -4- .
Remove inner bearing ring (output shaft).
Press rear inner bearing ring -1- off the housing until the Two-Arm Extractor Nr. 101 can be attached. Remove rear inner bearing ring using extractor and special tool Pressure Pieces 9656 .

Fig 13: Removing Inner Bearing Ring For 6th Gear
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove thrust plate.