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

Fig 2: Identifying Oil Pipe

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. 1.1. Unscrew screw -A-  and remove oil pipe -B-  .
2. 1.2. Unscrew screw plug -C-  and remove springs and balls.

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

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

Fig 3: Identifying Screw Plugs

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

Fig 4: Overview Of Differential Lock

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

   Courtesy 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: Loosening Gear Wheel For 1st Gear And Cylindrical-Roller Bearing On Output Shaft

   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 7: Identifying Synchronization

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. 7.1. Pull off fixed gear wheel for 3rd gear -1-  with gear wheel set for 1st-2nd gear using Puller Hook Nr. 105  and Pressure Pieces 9656  .
   Fig 8: Pulling Fixed Gear Wheel For 3rd Gear Using Puller Hook Nr. 105

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

Fig 9: Identifying Oil Pipe

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fig 11: Overview Of Output Shaft

Courtesy 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 ring -3, 5-  and four-point bearing -4-  .

   Fig 12: Pressing Of Cylindrical-Roller Bearing On Output Shaft

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fig 13: Disassembled View Of Drive Shaft

Courtesy 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 Drive Shaft In Vice

   Courtesy 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

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.