Assembling Gear Wheel Set For 5th-6th Gear

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Information

The prick punch marks on the shift sleeve must be centered with respect to the recesses in the guide sleeve.

Fig 1: Overview Of Front Gear Wheel Set
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Nut (self-locking)
2. Cylindrical-roller bearing
3. Thrust washer
4. Loose gear wheel, reverse gear
5. Synchronizer ring
6. Needle-roller bearing
7. Inner bearing ring
8. Shift sleeve
9. Washer
10. Screw
11. Shift fork (reverse gear)
1. 15 - Guide sleeve with snap ring
2. 16 - Loose gear wheel, 5th gear
3. 17 - Synchronizer ring
4. 18 - Needle-roller bearing
5. 19 - Inner bearing ring
6. 20 - Shift sleeve
7. 21 - Driver dog
8. 22 - Ball
9. 23 - Spring
10. 24 - Guide sleeve
11. 25 - Shift fork (5th and 6th gear)
12. 26 - Synchronizer ring
13. 27 - Loose gear wheel, 6th gear
14. 28 - Needle-roller bearing
15. 29 - Inner bearing ring
16. 30 - Thrust washer
17. 31 - Nut (self-locking)
18. 32 - Inner bearing ring
19. 33 - Fixed gear wheel, reverse gear
20. 34 - Spacer sleeve
21. 35 - Fixed gear wheel, 5th gear
22. 36 - Spacer sleeve
23. 37 - Fixed gear wheel, 6th gear
24. 38 - Housing

Install inner bearing ring.
1. 1.1. Fit thrust washer -30- on the output shaft.
2. 1.2. Heat inner bearing ring -29- to → Temperature: 120°C and fit it on the output shaft.
Fit fixed gear wheel for 6th gear on the drive shaft.
The large collar on the fixed gear wheel for 6th gear -37- must be pointing towards the spacer sleeve -36- .

Check the synchronizer rings for wear.

To do this, press the synchronizer rings onto the gear wheel cones and measure the gap -A- with a feeler gauge.

Fig 2: Checking Synchronizer Ring Wear

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Location	Description	Type	Basic value	Tolerance 1	Tolerance 2
Synchronizer ring installation dimension (new)		Nominal value	0.9 mm
Synchronizer ring wear		Nominal value	0.6 mm	+0.1 mm

Install 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 3: Identifying Synchronization
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Fig 4: Identifying Gear Wheel Set
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1. 4.1. Assemble gear wheel set for 5th-6th gear (synchronization).
  On the steel synchronizer ring, the rectangular indentations of the synchronizer ring -A- must be positioned above the driver dogs -B- .
2. 4.2. Install gear wheel set for 5th-6th gear.
  Fit gear wheel set for 5th-6th gear (synchronization) with loose gear wheels for 5th-6th gear, needle-roller bearing -18- and shift fork -25- on the output shaft.
Install inner bearing ring.
Heat inner bearing ring -19- to → Temperature: 120°C and fit it on the output shaft.
Fit fixed gear wheel for 5th gear on the drive shaft.
1. 6.1. Fit spacer sleeve -36- on the drive shaft.
2. 6.2. Fit fixed gear wheel for 5th gear on the drive shaft.
  The large collar on the fixed gear wheel for 5th gear -35- must be pointing towards the spacer sleeve -36- .
3. 6.3. Fit spacer sleeve -34- on the drive shaft.
Install gear wheel set for reverse gear.
1. 7.1. Assemble gear wheel set for reverse gear (synchronization).
2. 7.2. Install gear wheel set for reverse gear.
  Fit gear wheel set for reverse gear (synchronization) with loose gear wheel -4- , needle-roller bearing -6- and shift fork -11- on the output shaft.
Secure the shift forks.
Screw in screws -A- on the shift forks.

→ Tightening torque: 18 Nm (13 ft. lb.)

Fig 5: Identifying Shift Fork For Front Gear Wheel Set
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Tighten nuts on the input and output shafts.
Information

The transmission must be supported at the drive and output shafts when loosening and tightening nuts.

Tighten nut on output shaft to -2- → Tightening torque: 300 Nm (222 ft. lb.) .

Tighten nut on drive shaft to -1- → Tightening torque: 200 Nm (148 ft. lb.) .

Fig 6: Identifying Nuts On Input And Output Shafts
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