Volume I: Overall vehicle -General

General
0
Maintenance. diagnosis 03
Engine
Engine 1
Engine -Crankcase, mounting 10
Engine -Crankshaft, pistons 13
Engine -Cylinder head, valve drive 15
Engine -Lubrication 17
Engine -Cooling 19
Fuel, exhaust system, engine electrical system 2
Fuel supply, control
20
Exhaust system -Turbocharging 21
Fuel system, electronic injection 24
Fuel system, K-Jetronic
25
Exhaust system 26
Starter, power supply, GRA 27
Ignition system 28

Volume II: Transmission 3

Transmission Clutch, control
Manual transmission
30
Manual transmission -Controls, case 34
Manual transmission -Gears. shafts, inner operation 35
Final drive, differential, differential lock 39

Volume III: Transmission 3

Transmission Automatic transmission -Torque converter 32
Automatic Automatic transmission -Controls, case 37
transmission Automatic transmission -Gears, control 38
Final drive, differential, differential lock 39

Volume IV: Chassis 4

Chassis Front wheel suspension, drive shaft 40
Rear wheel suspension, drive shaft 42
Wheels, tires, alignment 44
Anti-Lock System (ABS) 45
Brakes -Mechanical 46
Brakes -Hydraulics, regulator, booster 47
Steering 48
Repair group survey 911 Carrera (993)

Volume V: Body 5
Body Body front section 50
Body center section, roof, frame 51
Body rear section 53
Hoods, lids 55
Front doors, Central Locking System 57

Exterior body equipment 6

Sunroof 60
Soft top, hardtop 61
Bumpers 63
Glasses, window control 64
Exterior equipment 66
Interior equipment, passenger protection 68

Interior body equipment 7

Trim, insulation 70
Seat frames 72
Seat upholstery, covers 74

Volume VI: Air conditioning 8

Air conditioning Heater 80
Vehicle electrics Ventilation 85
Air conditioning 87
Auxiliary air conditioning system 88

Electrical system 9
Instruments, alarm 90
Radio, telephone, on-board computer 91
Windshield wipers and washer 92
Exterior lights, lamps, switches 94
Interior lights, lamps, switches 96

Volume VII: Electrical system 9

Wiring diagrams Wiring 97

Volume VIII: Diagnosis D

Diagnosis Self-diagnosis 03
DME Diagnosis 24
Tiptronic Diagnosis 37
PDAS Diagnosis 39
ABS Diagnosis 45
Airbag Diagnosis 68
Heater Diagnosis 80
Alarm Diagnosis 90
 Preface

Structure
The "Technical Litenure" for the "911 Carrera (993)" model is basically structured as before,
i.e. the structure follows the familiar repair groups.

Main groups: 0 Complete vehicle -General

1 Engine
2 Fuel, exhaust, engine electrical system
3 Transmission
4 Chassis
5 Body
6 Body equipment, outside
7 Body equipment, interior
8 Air conditioning
9 Electrical system
D Diagnosis

Layout
The layout in the below items remains unchanged throughout the repair manual

1. Table of tightening torques

2. Special tools required
3. Exploded views
4. Legends for the exploded views
5. Assembly notes / use of special tools

As a new feature, however, the former item 6 (Repair group diagnosis) is no longer filed in the
volume corresponding to the respective repair group. The Diagnosis test plans / diagnosis proce-
dures have been combined in a separate Diagnosis volume broken down according to the main
groups 0 to 9.

Another new feature is that the contents of the "Service Information Technik" are indicated in the
Repair Manual. This brochure concentrates on a description of the design and function of compo-
nents and of the new features introduced for a par1icular model year.
Service Number
All major repair procedures and repair descriptions are identified by a two- or four-digit Service
Number completed by two additional digits to identify the work that corresponds to the first six
digits of the working position number in the Working Times and Damage Catalog.

Example: 30 37 37 Dismantling and assembling clutch control shaft

18

Presentation In the various documents

30 37 37 50 Working position no. from

Working Times and Damage Catalog,
consisting of repair group, component designation, activity and index

30 37 37 Six-digit number in Repair Manual,

consisting of repair group, component designation and activity

3037 Service number in Service Information,

consisting of repair group and component designation

Goal
The introduction of a service number in the "technical literature" is intended to facilitate stand-
ardization and positive identification to allow direct cross-referencing among the various documents.
This is of particular importance with regard to the use of electronic media.
 II Manual transmission
The Repair Manual of the 911 Carrera (993) also includes the 911 Carrera 4 manual (993 four-
wheel drive). The 911 Carrera (993) is the basic model covered by the repair operations described
in this Manual. "911 Carrera (993)" is also indicated in the header of each page.

Descriptions of repair operations that deviate for the 911 Carrera 4 will be included after the respec-
tive 911 Carrera section. The repair descriptions of both models are separated by a cover page. All
pages included after the cover page (separation sheet) have the "911 Carrera 4" heading. To facili-
tate distinction, the page numbering will start with 200.

3 Transmission
3 Technical data. 3 -1

Clutch, Control

Dismantling and assembling clutch control shaft. 30 -1

Checking clutch drive plate for wear. 30 -5
Removing and installing release bearing. 30 -7
Identification of clutch pressure plates. 30 -11
Pedals-adjustment overview .30-13
Disassembling and assembling pedals. 30 -15

Manual Transmission, Controls, Case

Removing and refitting the transmission. 34 -1

Dismantling and assembling transmission. 34 -3
Dismantling and assembling front transmission cover. 34 -17
Dismantling and assembling gear housing. 34 -23
Dismantling and assembling transmission housing. 34 -27
Adjusting gearshift 34-31

Manual Transmission -Gears, Shafts, Internal Controls

Removing and installing input shaft oil seal. 35 -1

Dismantling and assembling tensioning plate. 35 -3
Removingandinstallinginputshaft 35- 7
Dismantling and assembling input shaft. 35 -15
Dismantling and assembling output shaft. 35 -21
Removing and installing 5th gear (transmission is installed) 35 -23

Table of contents 1
Printed in Germany -16, 1996
Volume II Table of contents 911 Carrera (993)

39 Final Drive, Differential, Differential Lock

39 09 19 Removing and installing differential. ... .39 -1
39 09 37 Dismantling and assembling differential. . .39- 5
39 08 15 Adjustingdriveset .39 -11
911 Carrera (993) Service Information Technlk

Survey of contents of Service Information Technik '95

The Service Infonnatlon gives a detailed description of the technical features of the ne1N
911 Carrera.

Rep. Gr. Pagle

Engine
General 1 -1
Engine cross-sections 10 1 -4
Full-load curve 1 -6
Belt pulley 13 1 -8
Pistons 13 1 -10
Hydraulic valve lash adjuster 15 1 -16
Setting the timing 15 1 -18
USA -auxiliary air pump 1 -19

Fuel and ignition systems

General 2 -1
DME -Schematic 24 2- 2
Fuel -air flow 24 2- 3
Exhaust gas flow 26 2- 5
DME control unit 2.10.1 24 2- 9
Mass air flow sensor 24 2-12
Throttle potentiometer 24 2 -18

Ignition system 28 2 -24

Plausibility test 2 -~~8
2-~~9
Diagnosis
Auxiliary air pump 26 2 -33

Power transmission

Transmission 30 3 -1

Clutch 30 3- 2
Manual transmission 34 3- 3
Transmission ratios 3- 6
Gear set 35 3- 8
35 3- 9
Synchromesh
Final drive 39 3 -13
3 -15
Oil supply
Porsche Tiptronic 37 3 -16
Modifications for the '95 model year 3 -17
 Rep. Gr. Page

Running gear
General 4 -1
Front axle 40 4- 2
Steering 48 4- 7
Rear axle 42 4- 8
Elasto-kinematic toe correction 42 4-12
Coil springs (layout) 42 4 -13
Wheels, tires 44 4 -15
Suspension alignment 44 4-17
Brakes 47 4 -20
Bleeding the brakes 47 4 -23
ABSS 45 4 -24
Operation of the ABD 45 4 -30
Diagnosis ABS/ABD 45 4 -34

Body
General 5 -1
Constructional dimensions 50 5- 4
Aerodynamics and air ducting 50 5- 8

Body equipment
Body equipment 6 -1
Color scheme as of 1995 model year 60 6- 1
Windows 64 6- 8
Airbag system 68 6-14

Body -interior trim

Body -interior trim 70 7 -1

Seats 72 7- 5

Heating, air conditioning, ventilation

Particle filter 85 8- 1
Air ducting 80 8- 3
Heating -air conditioning unit 85 8 - 5
Heating -air conditioning unit 87 8- 6
Series resistor of rear blower 80 8- 9
911 Carrera (993) Service Infonnatlon Technik

Rep. Gr. Page

Electrical system

Instruments 90 9- 1
Alarm system/central locking system 90 9- 3
Heated rear window 64 9- 6
Central Information System (Z I) 91 9- 7
Radio "Alpine 7807" 91 9-'10
Sound package, DSP-System 91
Windshield wiper and washer system 92
Headlights 94
Front end light cluster 94
Taillights 94
Engine compartment baseplate 97
Wiring diagram

Summary
Maintenance 0 -1
Number ranges 0- 4
Technical data 0- 5

c
911 Carrera (993) Transmission

3 Technical data

6 speed manual transmission G 50 I 20 I 21 for 911 Carrera (993)

installed in: Model year

Type Equipment

6 speed 911 Carrera '94...'96

G 50/21
worldwide
except USA,
CH, A

6 speed 911 Carrera '94...'96

G 50/20
USA, CH, A

911 Carrera '97

worldwide
 Transmission 911 Carrera (993)

3 Technical data

6-speed manual transmission, type G 50/31/32/33 for 911 Carrera AS

Type Code Design installed in: Model year

G50/31 6-speed 911 Carrera AS '95f96

(basic vehicle)

G50/32 6-speed 911 Carrera AS '95(96

(Clubsport)

G50/33 6-speed 911 Carrera AS '95f96 8

(basic vehicle
and Clubsport)
Switzerland

Apart from a few differences, the transmission of the Carrera AS has a similar design to Carrera
transmissions G50/20/21; the repair procedures are also similar.

The major differences are as follows:

different gear ratios

-2nd gear wheel splined to drive shaft

steel/molybdenum synchronizer ring (type G50/32 only)

-limited-slip differential as standard equipment (locking values 40 % under acceleration,

65% under deceleration)

harder gearbox bearing

 3 Technical data

Structure of transmission numbers

G5021 1 05641

T
Transmission type
T
Index of variations
T
Serial no.
within the assembly no. e.g. 05641
1 = normal differential
2 = limited slip differential

~I

-
\

3-3

~
911 Carrera (993) Transmission

3 Technical data

Manual transmission for 911 Carrera (993)

General data Manual transmission G 50 I 21 I 20

Transmission ratios G50/21 G50/20

Z1 Z2 = Z2 : Z1 21 Z2 = Z2 : 21

1 st gear 11 : 42 = 3.818 11 : 42 = 3.818

2nd gear 20 : 43 = 2.150 21 : 43 = 2.048

3rd gear 25 : 39 = 1.560 27 : 38 = 1.407

4th gear 33 : 41 = 1.242 34:38=1.118

5th gear 37 : 38 = 1.027 38 : 35 = 0.921

41 :42=1.024* 42 : 39 = 0.928**

6th gear 39 : 32 = 0.820 40 : 31 = 0.775

Rev. gear 14 : 40 = 2.857 14:40=2.857

Final drive Hypoid bevel-gear drive with 16 mm offset

Transmission 9: 31 = 3.444 9 : 31 = 3.444

Final drive

Capacity 3.6 liter multigrade transmission oil SAE 75 W 90

of API classification GL 5 (or MIL-L 2105 B)

* introduction 15 December 1994

** introduction 7 December 1994
 Transmission 911 Carrera (993)

3 Technical data

Manual transmission for Carrera AS

General data Manual transmission G 50 I 31 I 32 I 33

Ratios G50/31 G50/32 G50/33

Z1 Z2 = Z2 : Z1 Z1 Z2 = Z2 : Z1 Z1 Z2 = Z2 : Z1

1 st gear 13: 41 = 3.154 13 : 41 = 3.154 13 : 41 = 3.154

2nd gear 20 : 40 = 2.000 20 : 40 = 2.000 20 : 40 = 2.000

3rd gear 23 : 35 = 1.522 23 : 35 = 1.522 27 : 38 = 1.407

4th gear 33: 41 = 1.242 29 : 36 = 1.241 34 : 38 = 1.118

5th gear 41 : 42 = 1.024 32:33=1.031 37 : 36 = 0.973

6th gear 39 : 32 = 0.821 35 : 29 = 0.829 39 : 32 = 0.821

Reverse 14 : 40 = 2.857 14: 40 = 2.857 14 : 40 = 2.857

Final drive Hypoid bevel final drive with 16 mm offset

Final drive ratio 9 : 31 = 3.444 9 : 31 = 3.444 9 : 31 = 3.444

Filling capacities* 3.6 I multi-grade transmission oil SAE 75 W 90,

API specification GL 5 (or MIL-L 2105 B)

*933 GT 2 (transmission type G 50/53) only Veedol SAF 44,

3 Technical data

Tightening torques for manual transmission and transmission mounts

Location Thread Tightening torques
Nm (ttlb.)

Hexagon head bolt / M 10 44 (32)

halfshaft flange

Oil cup to tensioning M5 6 (4)

plate (micro-sealed)

Ring gear to differential M 12 x 1 .25 200 (148)

housing (Hexagon head
bolt with serrated mating
surface)

Transmission mount to body M 10 x 70 46 (34)

Transmission mount to transmission M 12 x 1.5 85 (63)

(lock nut)

Longitudinal mount to transmission M 12 x 1.5 x 65 85 (63)

Longitudinal mount to transmission M 10 30 (22)

(lock nut)
911 Carrera (993) Clutch, Controls

Note:
No. Designation Oty. Removal Installation

1 Hexagon head bolt 1

M 6 x 16

2 Bracket

3 Bearing cover 1 Pack with grease (use

Olista Longtime 3 EP)

4 Needle-roller bearing with 1 Install in correct posi-

assembly hole tion. assembly hole
points towards outside

5 Release lever shaft 1 Pull out with hexagon Do not grease plastic
head screw M 6 x 40 bushing bearing suriace

6 Sealing ring 2 Check, replace if re-

quired, install in correct
position

7 Release lever 1

8 Plastic bushing 2 Do not grease

9 Needle-roller bearing with- 1

out assembly hole

Note

Lubricate all sliding suriaces of the clutch release mechanism -except for the items indicated in
the list -with Olista Longtime 3 EP. Part No. 000.043.024.00.
Assembly notes

Removing bearing cover

Insel1 a suitable screwdriver across rectan-

gular cutout (of clutch bell housing) and push
bearing cover out of bearing hole.

1865-30

Installing bearing cover

Locate bearing cover with assembly mandrel,

e.g. Special Tool 9287 (drift for headlamp
beam range adjusters) and carefully press in
to stop.

'866-30
 911 Carrera (993) Clutch, Controls

30 56 01 Checking clutch drive plate for wear

(clutch drive plate removed) Wear limit X is 0.3 mm (see drawing).

When the drive plate is new, this dimension is
Checking: approx. 1.0 mm.
Using a depth gage or sliding calipers, Note that lining wear is not linear, i.e. not at
measure distance X from surface of lining to a steady rate throughout the clutch's opera-
rivet head. ting life. The way in which the lining material
beds down and is compressed initially sug-
Note gests that greater lining wear is taking place,
Measure only at the beaded-over side of the but as the car is driven fur1her, the rate of
wear declines considerably.
rivet head.

0 <:.:.J

" ;
64o-~

646-:xJ

1 -Lining
2 -Drive plate/lining spring

30 56 01 Checking clutch drive plate for wear 30 -5

Printed in Germany -IV, 1994
;-r-'1
911 Carrera (993) Clutch, Controls

30 52 19 Removing and installing release bearing

1 3

11003-30

3052 19 Removing and Installing release bearing

 Note:
No. Designation Oty. Removal Installation

Snap ring 1 use pointed pliers to observe correct seating

remove, pressing down of snap ring
thrust plate in a press

2 Thrust washer 1 groove must face

snap ring
3 Release bearing 1 check, do not wash out,
just wipe with a dry cloth

4 Spring washer 1 install in correct position

5 Spacer 2 always insert

2 spacers

6 Thrust plate 1 check for wear. replace 8

if required
Assembly notes

1. The snap ring can only be fitted with a shop 3. Do not grease sliding surfaces of release
press. Use a wooden block as a thrust bearing and guide tube.
piece.

'-

1867-30

1000-30

4. The guide sleeve is slotted (uneven outline

2. Install spring washer in correct positiion. -see arrow).

1001-30 1868-30
911 Carrera (993) Clutch, Controls

3052 Identification of clutch pressure plates

To avoid confusion, the pressure plates are

color-marked for positive identification.

836-~

Color marking:

968 Green
911 Carrera 2/4 Blue
911 Carrera (993) No mark
911 Turbo 3.6 Red

30 52 Identification of clutch pressure plates 30 -11

Printed in Germany -IV. 1994
 911 Carrera (993) Clutch, Operation

30 Pedals -adjustment overview

Adjusting clutch pedal

Note

The following points are prerequisites for

proper operation of the clutch and must be
observed when adjusting the pedals:
-Proper bleeding of the hydraulic clutch '(,
1"
system
-Tightness of the hydraulic system 3
/
-Proper setting of the servo spring
-Returning of pedal to initial position
-Pedal travel limited by properly adjusted
floor board stopper
-Installation position of pedals in
accordance with standard situation.

Checking and adjusting work

1. Checking the pedal return

(returning force)
Try to return the pedal to its initial position
by applying at least 30 N (spring scale).
The pedal must not yield. If it does yield
(= insufficient returning force), the servo
spring pre-load must be reduced or set to
the dimension A = 6 mm (see 2.).

2. Setting servo spring (dim. A = 6 mm).

The servo spring is set by turning the
hexagon socket head bolt arrow I no. 1
(chart 1097-30). The distance (dimension AI
figure 1113-30) between the inner face of
the bolt head and the rocker must be 6 mm.

3. Checking pedal travel (dim. B = 150 mm).

Measured from the center of the pedal plate,
the pedal travel must be 150 mm + 5 mm.
If necessary, adjust or limit the pedal travel
on the floor board stopper (fig. 1098-30 on
p. 30-14).

30 -13
 Clutch, Operation 911 Carrera (993)

If the brake light lights up after a brake travel

of less than 6 mm, the brake light switch (2)
must be turned to the right until it responds
within the range of tolerance. Do not damage
the electric wire and the plug. If the adjust-
ment range of the brake light switch is not
sufficient, the brake pedal must be adjusted
at the ball joint of brake push rod 3 (by
shortening push rod).

If the brake light lights up after a pedal travel

of more than 16 mm, the brake pedal must be
1098-30 adjusted at the ball joint of the brake push rod
(by extending push rod) until the brake pedal
4. Clutch play. switch responds within the range of tolerance.
The clutch master cylinder is fitted with an
internal stopper. The push rod and the Note
clutch pedal are always pressed against this Usually, the brake pedal plate is roughly at
stopper by the servo spring. Due to auto- the same height as the clutch pedal plate
matic hydraulic readjustment of the clutch, (plus/minus 3 mm).
the clutch play cannot be assessed by
checking the clutch pedal.

Adjusting microswitch

The microswitch (on vehicles with cruise

control) is adjusted by a sliding movement
after the fastening screws have been slack-
ened. The microswitch must be triggered
(clicking sound) on the first few milimeters of
pedal travel.

1097-30

Adjusting brake light switch

Throttle operation
The brake light must light up after a brake Check for smooth operation and at wide open
pedal travel of 6-16 mm (measured from the
throttle.
center of the pedal plate).
30 Disassembling and assembling pedals

Includes: removing and installing pedals

Important note

Remove the pedals together with the

clutch master cylinder.
To do so, slacken the hydraulic lines on the
clutch master cylinder. Release servo spring
partially (move clutch pedal into de-clutched
position).
Plug the hydraulic lines or clamp off the
supply line using a commercially available
hose clamp. Also plug the connecting bores 2358-30
of the clutch master cylinder.
3. Remove clutch master cylinder. Then lock
rocker / servo spring. To do so, move clutch
pedal into de-clutched position.
In this position, operate clutch pedal (by
pulling it backwards), until an auxiliary tool
Disassembling pedals (steel pin with 8 mm 0) can be inserted
from the side into the bore of the rocker.
1. Mount brake pedal of pedal system onto a
vise -using protective jaws -.

2. Turn adjustment screw for the servo spring

/~
to the left (counter-clockwise), until the leg ~
of the servo spring fits closely to the rocker
(arrow).

/ ' f'

2357-30
 4. Release servo spring in two steps.
Use an appropriate spring tensioning tool,
e.g. brake spring pincers by Hazet (Hazet Il /"

no. 797) to load and release the servo

spring. To protect the mounting block, use a
~
liner when applying the pincers.
~ 7
First step:
Remove the support pin (arrow) on lever " '---

no. 9 using a screw driver.

Caution: Do not get into the operating
~I 7
range of the rocker, the servo spring or 2366-30
the levers with your fingers or hands.
5. On vehicles with cruise control:
Mark position of microswitch.
Remove microswitch.

@ 6. Slacken fastening nut no. 28 on operating

~
lever no. 9.
Remove lever from clutch pedal shaft -
through the lateral bore on the mounting
block -using a copper or brass mandrel.
If lever can be removed, continue with
0
IrJ item 8.

Important note
c::: If lever no. 9 cannot be removed from the
clutch pedal shaft without damaging the
9 28 clutch pedal shaft (which may occur due to
tolerances), continue with item 7.
2370-30

Second step:
First load the servo spring through the rocker
until the auxiliary tool (steel pin with 8 mm 0)
can be removed easily from the bore of the
rocker. Then release the servo spring by
opening the pincers.

.,
'/'~
'",
~
 2360-30

If the lever cannot be removed with a puller,

the clutch pedal shaft must be destroyed.
2348-30
To do so, separate clutch pedal from pedal
shaft (by sawing) with bearing tube no. 11
7. If lever no. 9 cannot be removed from the slackened (screw no. 10 removed).
clutch pedal shaft without damaging the
clutch pedal shaft (which may occur due If lever no. 9 can be reused (see -Note -on
to tolerances), part of the mounting block page 30-18), remove the lever from the pedal.
must be sawed off (arrow / dotted line). To do so, use plate VW 401 and an appropri-
Then remove the lever using a commer- ate bushing, e.g. Matra 40-503.
cially available two-claw puller.

2361-30

2359-30

30-17
8. Lift out clutch pedal shaft with clutch pedal. 9. Remove shaft no. 7 from mounting block.
Remove bearing sleeve no. 5. servo spring
no. 6 and the assembly of lever no. 9 and
rocker no. 16.
Note

If the pedals were disassembled because of

the complaint -sometimes the clutch pedal
does not return fully -, replace lever no. 9
(fig. 2348-30 / new, modified version with
optimized kinematics).

> Distinguishing old and new levers

Part number on part.

> Previous version:

Part no. 99342351900 or 2365-30

99342351901 (gold-colored).

10. Remove bearing pipe no. 11 and brake

pedal.
> Modified I new version:

Part no. 993423 519 02 (olive).

In the beginning, the modified, new
levers were golden as well.

2363-30
Assembling pedals

2. Insert brake pedal into mounting block. If

1. Check all parts, replace any parts, if
necessary, fit a shim (arrow) between the
required.
If the bushings must be replaced, use an brake pedal and the mounting block (to

appropriate mandrel for removal or installa- compensate for the axial play). The shim is
not always present.
tion. Coat all bearings and slide faces
When replacing the mounting block or
with a Teflon-compatible low tempera-
the brake pedal, determine the thickness
ture grease -e.g. Glissando by DEA
of the shim (if present and/or required):
(Texaco).
With the brake pedal installed, determine by
trial and error which shim can be inserted.
There are shims with two different thick-
nesses available.
Insert bearing tube no. 11.
Insert screw no. 1O, but do not tighten it yet.
Important: Tighten screw no. 10 only
after installing the pedals.

2348-30

Note
Check the mounting block for deformations 2363/1-30

(might stem from removal of lever no. 9).

If necessary, remove the mounting block.
 3. Preassemble lever no. 9, rocker no. 16 and 5. To preload the servo spring, mount the
connecting pieces no. 13. If necessary brake pedal of the completed pedal system
(after installaton of a new rocker), turn onto a vise -using protective jaws.
adjustment screw no. 17 until the leg of the
servo spring fits closely to the rocker 6. Preload servo spring as follows:
(arrow). Install only levers no. 9 with op- Use an appropriate spring tensioning tool,
timized kinematics. See note on p. 30-18. e.g. brake spring pincers by Hazet (Hazet
no. 797), to preload the servo spring until
an auxiliary tool (steel pin with 8 mm 0) can
be inserted into the bore of the rocker from
29 the side. To protect the mounting block, use
7 I
I I a liner when applying the pincers.
I

.P
()

2364-30
"i::A; ~I
\~~
4. Insert bearing sleeve no. 5, servo spring
~
no. 6 and the assembly of lever no. 9 and ~j 2
rocker no. 16 into the mounting block.
Insert and fasten shaft no. 7. 2366/1-30

7. Insert clutch pedal shaft with clutch pedal

no. 2.
Fit lever no. 9 in its correct position to the
clutch pedal shaft (notch on lever must face
tooth gap of shaft).
Fit fastening nut no. 28.
Do not tighten fastening nut yet, (see
next item).

2365/1-30

~
911 Carrera (993) Clutch, Operation

If the clutch master cylinder does not fit

closely to the mounting block, rework the
mounting block's contact surface using a
plastic hammer.

11. When replacing the mounting block,

re-install those parts of the old mounting
block that are required.

2367-30
12. Set adjustment screw of servo spring
(no. 17) to the dimension of 6 mm
8. Remove auxiliary tool (steel pin to preload
(see page 30-13).
servo spring) from rocker. To do so, move
clutch pedal backwards (towards clutch posi-
tion) carefully and only slightly. Remove 13. Install pedals with the servo spring
the steel pin as soon as it is no longer released partially (clutch pedal in
under load. de-clutched position).
Then tighten fastening nut no. 28,
tightening torque 34 Nm. Important note

Note Then tighten screw of bearing tube (see

item 2 on page 30-19).
If the auxiliary tool (steel pin) is not
removed with utmost care or if the fasten-
ing nut is tightened with the auxiliary tool 14. Connect lines of hydraulic clutch system
still inserted, the rocker may get damaged to clutch master cylinder. Bleed clutch
in the area of the bore.
system.

Note
9. On vehicles with cruise control, install the
Carry out adjustments, e.g. adjusting brake
microswitch.
light switch, and inspections, e.g. limiting /
adjusting pedal travel.
10. Install the clutch master cylinder.
The adjustment jobs are described on pages
On vehicles with cruise control, adjust the
microswitch by sliding it into the proper 30-13 and 30-14.

position.
The microswitch must be triggered (click-
ing sound) on the first few milimeters of
pedal travel.
 34 35 27 Removing and refitting the transmission

Removing the transmission

Remove wire from starter and wire from 3. Undo four fastening nuts and separate trans-
reverse light switch. mission from engine. Undo upper fastening
nut from starter using Special Tool P 119.
2. Remove M 6 x 16 hexagon head bolt, brack-
et and mount cover. Pullout release lever
shaft using an M 6 x 40 hexagon head bolt.

~
~",--- -J '-"

~;;=~~==:~J

~
1391-10

1388-10

.~I
 Manual Transmission, Controls, Case 911 Carrera (993)

Refitting the transmission

Note:
Apply a very thin coat of Olista Longtime 3 EP
to input shaft splines (for corrosion protection
only).

Engage release fork into release bearing

and use a suitable length of adhesive tape
to locate it provisionally in installation posi-
tion.

1390-10

2. Refit transmission to engine.

3. Engage release lever shaft with seals into

release fork.

4. Remove locating tape from release fork

across assembly hole.

5. Install needle-roller bearing, mount cover

and bracket and tighten down with M 6 x 16
hexagon head bolt (also refer to assembly
notes, Group 30, page 30 -1).
34 35 37 Dismantling and assembling transmission

Tools

34 -3
 Manual Transmission, Controls, Case 911 Carrera (993)

34 35 37 Dismantling and assembling transmission

911 Carrera (993) Manual Transmission, Controls, Case

34 35 37 Dismantling and assembling transmission 34 -5

Manual Transmission, Controls, Case 911 Carrera (993)
911 Carrera (993) Manual Transmission, Controls, Case

34 35 37 Dismantling and assembling transmission 34 -7

Printed in Germany -20, 1997

 Note:
No. Designation Oty. Removal Installation

Transmission shafts without recesses for securing the hexagon nuts have been installed
since September 1995.
Self-locking hexagon nuts are used on these shafts, and these nuts must always be replaced
in every transmission repair.

** As a result of tolerances, the bearing inner rings (no. 29 and 36) may either form a force fit on the
shaft or have a certain amount of play.
911 Carrera (993) Manual Transmission, Controls, Case

Dismantling and assembly notes

Note

If the shift rods are moved across the neutral

or gear latching positions when the transmis-
sion is dismantled or assembled, the small in-
termediate locks (see page 35 -13) may drop
out inadvertently.

Dismantling
1. Engage 6th gear, lock input shaft with
Special Tool 9253 and release hexagon
head nuts for output and input shafts.
1641-34

A = Arms of puller 9284

Assembly

1. To check synchronizing rings, push rings

onto the tapers of the gearwheels and
measure gap "A" with a feeler gauge.

Installation dimension (new) = min. 0.9 mm

Wear limit = 0.6...0.7 mm

503-34

2. Engage fourth gear and pull off inner race

of needle roller bearing (5th gear).

518-35
2. Engage fourth gear and fit all gearwheels.

3. Adjust inner shift rod until all gears may be

preselected freely without notching. To ad-
just, undo hexagon head bolts of tensioning
plate and rotate eccentric bushing.

g
~

527-34

A = Tensioning plate
B = Eccentric bushing

4. To check, shift through all gears, using a

long M 8 bolt that is screwed into the inner
shift rod.
34 35 37 Dismantling and assembling transmission
Manual Transmission, Controls, Case 911 Carrera (993)
911 Carrera (993) Manual Transmission, Controls, Case

Note:
No. Designation I Qty. Removal Installation

18 Synchronizing ring 1 Mark for reinstallation Check for wear. Fit with
the same gearwheel.
Drivers must engage in
the cutouts in the tapered
ring. Three lugs face
driver dogs

19 Needle roller bearing Fit with the same gear-

wheel

20 Inner race 1 Fit with the same gear-

wheel. Heat to approx.
120 'C

21 Shift sleeve 1 Insert complete with

guide sleeve and shift
rods. The missing tooth
of the internal teeth of the
guide sleeve (No. 28)
must be aligned exactly
above the oil bore of the
output shaft.

22 Shift rod with pinned shift 1

fork

23 Shift rod (reverse) 1

24 Spacer 1 Apply stiff grease to
insert into shift rod

25 Driver dog 3 Place into correct position

26 Ball 3

27 Spring 3

34 -13
 Note:
No. Designation Qty. Removal Installation

28 Guide sleeve 1 Missing tooth of internal

teeth must be placed ex-
actly above oil bore of
output shaft
29 Synchronizing ring 1 Mark for reinstallation Check for wear. Fit with
the same gearwheel.
Drivers must engage into
the cutouts in the tapered
ring. The lugs face the
driver dogs.

30 Tapered ring 1 Mark for reinstallation Fit with the same gear-
wheel. Tabs must
engage into the cutouts
in the loose gearwheel

31 Friction ring 1 Mark for reinstallation Fit with the same gear-
wheel

1 Mark for reinstallation Fit with the same gear-

wheel

34 Inner race 1 Mark for reinstallation. Fit with the same gear-
Pull off across fixed wheel. Heat to approx.
gearwheel No. 36 120 'C

35 Thrust washer 1

36 Fixed gearwheel (3rd gear) 1

37 Spacer sleeve 1

38 Hexagon head bolt 1

(micro-sealed)

39 Washer 1

40 Spacer sleeve 1
911 Carrera (993) Manual Transmission, Controls, Case

Note:
No. I Designation Qty. Removal Installation

41 Retaining plate 1
42 Hexagon head nut 10 Tighten to 23 Nm (17 ftlb.)
43 Tensioning plate with gear 1
set

44 Adjusting washer "83" x Note number and thick- Redetermine thickness if

ness for reinstallation required
45 Oval-head screw 2 Tighten to 10 Nm (7 ftlb.)
46 Guide tube 1
47 Shaft seal 1 Refer to page 35 -1 Do not fit until gear set
has been fitted (refer to
page 35 -1)

48 Transmission housing 1

Note
Due to the tolerances (transition fit), the inner bearing rings (nos. 11, 20 and 34) may have clear-
ance or press-fit on the shaft.

Modifications to the synchromesh and the shift sleeve for 1 st and 2n gear are described on
page 35 -14.
Dismantling and assembly notes

Dismantling Note

Do not move shift rods across the neutral or

Note gear stop position as this may cause the
small spacers to drop out inadvertently (refer
To facilitate assembly, do not remove the
to page 35 -13).
complete gear set assembly but partially
dismantle the installed drive pinion.

Assembly

1. The number of adjusting shims "53" noted

during dismantling or the number of adjust-
ing shims noted when the drive pinion was
adjusted should be placed onto the studs in
the housing until the equivalent thickness is
obtained.

\~\

506-34

2. Fit fully assembled gear set complete with

inner shift rod and tighten tensioning plate
fastening nuts to 23 Nm (17 ftlb.) (refer to
page 35 -7).
34 55 37 Dismantling and assembling front transmission cover

Tools

34 55 37 Dismantling and assembling front transmission cover 34 -17

Printed in Germany -20, 1997
 Manual Transmission, Controls, Case 911 Carrera (993)

3455 19 Dismantling and assembling front transmission cover

1 16 2
8
I 9 -({;j::9- 1211
II I
I \

4
--
5
3
Ii

~jv I
7
6

10 14 ~~/
I
13

1649.34
 Note:
No. Designation Qty. Removal Installation

1 Hexagon-head bolt 1 Torque: 35 Nm (26 f1lb.)

2 Bolt with pin 1 Insert in correct position
3 Reverse idler gear 1 Small collar points towards
hexagon-head bolt (no. 1)
4 Thrust washer (2.0 mm) 1
5 Thrust washer (1.5 mm) 1 Do not confuse with
washer no. 4
6 Thrust washer (1.5 mm) 1 Do not confuse with
washer no. 4
7 Needle-roller assembly 1
8 Shaft seal 1 Pack the area between
dust lip and sealing lip
with grease (e.g.
Optimol HT2 + 2 EP);
press in to stop with
mandrel 9254 (p. A)

9 Ball sleeve (long) 1 Press out from the inside. Press in to stop with
using a suitable mandrelI Special tool 9254 (p. B)
(,e.g. 9515)'Pull
10 Ball sleeve (short) 1 out with a suitable Press in to stop with
internal puller (e.g. Special tool 9254 (p. A)
Schrem 14 -20) and
Dunch VW 771

11 Retaining ring 1
12 Cylindrical roller bearing 1 Pull out with suitable Heat cover to approx.
internal puller (e.g. 120 'C and press in to
Schrem 30 -40) stop
13 Retaining ring 1

I
 911 Carrera (993) Manual Transmission, Controls, Case

Notes on assembly

1. Press in ball sleeves, shaft seal and trans- 2. Reassemble reverse idler gear with thrust
mission bearing to correct position. washers and bolt in correct position (refer to
exploded view). With thrust washers and
bolt located correctly, the end clearance of
the reverse idler gear is 0.15...0.35 mm.

c
1642-34

~
1 -Short ball sleeve (press in flush)
520-34

2 -Long ball sleeve

A = Feeler gauge
3 -Shaft seal
3. Check end clearance of reverse idler gear
A -Assembly mark (must point upwards) with feeler gauge.

3
 911 Carrera (993) Manual Transmission, Controls, Case

34 52 37 Dismantling and assembling gear housing

Tools

Designation Special tool Order number Explanation

1 Mandrel P 254 000.721.254.00

2 Thrust piece P 254 a 000.721.254.10

3 Thrust piece P 254 b 000.721.254.20

4 Mandrel 9254 000.721.925.40

No.
 Manual Transmission, Controls, Case 911 Carrera (993)

34 52 37 Dismantling and assembling gear housing

911 Carrera (993) Manual Transmission, Controls, Case
34 37 37

Tools
 Manual Transmission, Controls, Case 911 Carrera (993)

34 37 37 Dismantling and assembling transmission housing

 Note:
No. Designation Oty. Removal Installation

Plug 1 Clean, tighten to 30 Nm

(22 ftlb.)
2 Seal 1 Replace
3 Vent 1 Tighten to 35 Nm (26
ftlb.). The hole in the
hexagon head must face
the front transmission
cover
4 Oval-head screw 2 Tighten to 10 Nm (7 ftlb.

5 Guide tube
6 Shaft seal 1 Do not fit until the gear
set has been fitted {also
I refer to page 35 -1}

7 Cover 1
8 Bushing 1 Push out with drift 9515, Do not grease or oil and
working from inside do not clean with sol-
towards outside vents (e.g. benzene).
Push in from inside with
drift 9515 until it is
seated against the stop.

9 Shaft seal Push in with Special Tool

9252 until it is seated
against the stop. Pace
space between dust lip
and sealing lip with
grease (e.g. Optimol
HT2 + 2EP)

10 Ball sleeve (long) 1 Pull out with suitable inter- Press in flush with
nal puller (e.g. Schrem Special Tool 9254
14 -20)

11 Ball sleeve (short) 4 Pull out with suitable inter- Press in flush with
nal puller (e.g. Schrem Special Tool 9254
14- 20)
 Note:
No. Designation Oty. Removal Installation

12 Bearing outer race 1 Heat transmission hous- Heat transmission hous-

ing to approx. 120 'C and ing to approx. 120 .C and
remove race with suitable press in with suitable
drift thrust piece
13 Bearing outer race 1 Heat transmission hous- Heat transmission hous- ,
I

ing to approx. 120 .C and ing to approx. 120 .C and

remove race with suitable press in with suitable
thrust piece (e.g. VW 513) thrust piece (e.g. 9247/4)
until it is seated against
the stop

14 Bearing outer race 1 Heat transmission hous- Heat transmission hous-

ing to approx. 120 .C and ing to approx. 120 .C andi
pull put with suitable inter- press in with Special
nal puller (e.g. Schrem Tools P 254 and P 254 b
50 -60) until it is seated against
the stop

15 Transmission housing 1
911 Carrera (993) Manual Transmission, Operation, Housing

34 Adjusting gear shift

1. Set the shift lever to the neutral position. 2. If the gearshift is correctly adjusted, there
The lever will automatically move to the should be no longitudinal inclination on the
3rd/4th gear plane (no adjustment possible) lower part of the lever, which is curved at
the top. The lower 900 part should be at
right angles to the central tube or
transmission tunnel.

3. Checking the adjustment: shift through all

the gears. whichever gear is selected, there
must be about the same space between the
front and rear consoles.

4. If necessary, correct the adjustment on the

ball of the adjustable guide tube (arrow).
One turn of the ball corresponds to a
change of about 3 to 5 mm in the angle of
the shift lever.
Caution: When tightening the lock nut,
2049A-34
make sure that you do not twist the balls in
relation to each other.

Drawing 644A shows the four-wheel drive version. On the rear-wheel drive version, the ball of the
guide tube (arrow) is installed on a transverse strut attached to the front axle cross member.
911 Carrera (993) Manual Transmission -Gears, Shafts, Internal Controls

35 50 19 Removing and installing input shaft oil seal

Removing 4. Screw in the hexagon-head bolt and pull

out oil seal.
1. Remove engine/transmission assembly and
separate transmission from engine.

2. Remove release bearing guide tube.

3. Screw Special Tool 9251 firmly into the oil

seal.

1653-34

Note

If the helical tension spring jumps out when

removing the seal, use a wire hook to pull it
off the input shaft.
1652.34
 35 Manual Transmission -Gears, Shafts, Internal Controls 911 Carrera (993)

Installing

1. Push assembling sleeve 9255 onto the 3. Use Special Tool 9256 to drive the oil seal
input shaft splines. into place.

/
./
~-
J' ,

).,

/.,~\
I

1654-34 1655-34

2. Pack oil seal area between dust lip and seal- 4. Install guide tube and tighten mounting
ing lip with grease (e.g. Optimal HT 2 + 2 EP). screws to 10 Nm (7 ftlb.).

~;~,;~
911 Carrera (993) Manual Transmission -Gears, Shafts, Internal Controls

Note:
No. Designation Oty. Removal Installation

1 Straight pin 4 With the shift rods fitted,

the springs (No.3) are
underload
2 Washer 4

3 Thrust spring 4
4 Locking bush 4

1
1

1
1
1 Install in correct position,
use 8 mm dia. locating
mandrel to locate relative
to tensioning plate hole

10 Ball 1
11 Thrust spring 1

12 Deflection lever 1
1 Mark for reinstallation Free length
= 51.3 + 0.5 mm
wire thickness = 1.5 mm. I
Do not cnfuse with s!Jring I
No. 14 !

1 Mark for reinstallation Free length

= 72.6 + 0.5 mm
wire thickness = 1.1 mm.
Do not confuse with
spring No. 13

2
Installation position of the locks

1709-35
911 Carrera (993) Manual Transmission -Gears, Shafts, Internal Controls

35 40 19 Removing and installing input shaft

Tools
35 40 19 Removing and installing input shaft
* see page 35 -14
* see page 35 -14
911 Carrera 4 (993) Manual Transmission -Gears, Shafts, Internal Controls
 Note:
No. Designation Qty. Removal Installation

1
1 Insert complete with
pinned shift rod / shift
fork (No. 42)
1

1
1
1
46 Tensioning plate 1

** Transmission shafts without recesses for securing the hexagon nuts have been installed since

Spetember 1995.
Self-locking hexagon nuts are used on these shafts, and these nuts must always be replaced
in every transmission repair.

35 -12 354019 Removing and installing input sh;aft

Removal and installing notes

Removal 3. Observe installation position of locks"

Note

Parts No.1 to 30 are removed with the

tensioning plate remaining fitted (refer to
page 34 -11).

Installation

Using a suitable flat iron bar, clamp tension-

ing plate in a vise in such a manner that the
hole for the shift rod locks is horizontal.

2. Check synchromesh of 1st and 2nd gears.

To do so, place friction ring, tapered ring
and synchronizing ring in correct position
onto gearwheel. Check gap "A" with a feeler
gauge.
Old design:
installation dimension (new) = 1709-35

1 .3 to 1.95 mm
wear dimension = 1.0 mm 1 = Shift rod 3rd and 4th gear
2 = Lock (short)
New design:
installation dimension (new) = 1.5 to 2.0 mm 3 = Shift rod 5th and 6th gear
wear dimension = 1.2 mm 4 = Intermediate lock
5 = Lock (long)
(see page 35 -14)
6 = Reverse shift rod
7 = Intermediate lock
8 = Lock (short)
9 = Shift rod 1 st and 2nd gear

Note

After fitting the shift rods, do not move them

across the neutral or gear latch positiorls as
this may cause the small intermediate II~cks
to drop out inadvertently.
To avoid inadvertent movement of the shift
rods, lock shift rods by engaging 4th gear.

1701-311
 Modified synchromesh on 1 st and 2nd gear

The following parts have been modified: Friction ring

shift sleeve (with three plunge-milled

grooves on the inside teeth).

-friction ring (changed dimensions and

marking 94)

From transmission no.:

G 5020 1 000 884

G 5020 2 000 883
G 5021 1 002 186
G 5021 2 001 230

compression spring 1904-35

(unloaded length 16.22 mm) A = marking

From transmission no.: Note

Old and new parts must not be installed

G 5020 1 000960
together in the same transmission. As only
G 5020 2 000927
the modified parts are now available, all the
G 5021 1002238
modified parts must be installed in the event
G 5021 2 001294
of repair work. The following points must be
noted:
Shift sleeve

Install the shift sleeve on the guide sleeve

with the punch marks "8" centered
between the balls.

-New installation and wear dimensions

installaton (new) = 1.5...2.0 mm
wear dimension = 1.2 mm
(see also page 35 -13)

-Continuous groove" A" must point towards

2nd gear.
~

A = distinctive groove 1905-35

(must point towards 2nd gear)

~
911 Carrera (993) Manual Transmission, Gears, Shafts, Internal Controls

1906-35

1 = shift sleeve
2 = ball
3 = driver dog
4 = spring
A = groove
B = punch mark
C = 2nd gear side
D = 1 st gear side
 911 Carrera (993) Manual Transmission -Gears, Shafts, Internal Controls

35 40 37 Dismantling and assembling input shaft

Tools

Special tool Order number Explanation

Designation

1 Insert 9282 000.721.928.20

~000.721.910.50
2 Socket 9105

~
 Manual Transmission -Gears, Shafts, Internal Controls 911 Carrera (993)

35 40 37 Dismantling and assembling input shaft

911 Carrera 4 (993) Manual Transmission -Gears, Shafts, Internal Controls

Note:
~I- Designation Qty. Removal Installation

1 Hexagon head nut 1 Undo with Special Tools Use Special Tools 9282
(see note on Page 35 -19) 9282 and 9105 and 9105 and tighten to 1

250 Nm (184 ftlb.). Upse1

flange to lock I
I

2 Cylindrical roller bearing 1 Press off with suitable se- Heat to approx. 120 °C
parating device (e.g. Kuk-
ko 17-1) across 2nd gear
fixed gearwheel

3 Bearing inner race 1 Press off with suitable se- Heat to approx. 120 °c
parating device (e.g. Kuk-
ko 17-1) across
I 2nd gear fixed gearwheel

4 Four-point bearing 1
5 Tensioning plate 1 Clamp in a vise (use pro.
tective jaws), insert lock
(long), engage 5th gear
and install input shaft
with pinned shift rod/shift
fork

6 Bearing inner race 1 Press off with suitable se- Heat to approx. 120 °C
parating device (e.g. Kuk-
ko 17-1)

7 Thrust washer 1 Large, face-ground side

faces needle cage

8 Loose gearwheel (4th 1 Replace only in pairs

gear)
9 Synchronizing ring 1 Mark for reinstallation Check for wear, install in
correct position using the
same gearwheel (lugs
face the driver dogs)

35 40 37 Dismantling and assembling input shaft 35 -17

Printed in Germany -20. 1997
* See note on page 35 -19

35 -18 35 40 37 Dismantling and assembling input st1aft

Dismantling and assembling notes

Note Assembling

Since 1 October 1994, the fixed wheel of se- 1. To inspect synchronizing rings, press rings
cond gear (no. 22) has been firmly fixed to onto the gear wheel tapers and use a feeler
the drive pinion; the needle cage (no. 19) gauge to measure gap "A".
runs directly on the polished shaft. The thrust
washer (no. 21) and the inner ring (no. 20) Assembly dimension (new) = 0.9 mm min.
are no longer fitted. Wear limit = 0.6 to 0.7 mm

Dismantling

1. Mount retaining plate 9282 in vise, fit input

shaft and undo hexagon-head nut with
Special Tool 9105.

518-35

J- Note

Transmission shafts without recesses for secu-

ring the hexagon nuts have been installed
535-35 since September 1995.

2. Use a suitable tool (e.g. Kukko 17 -1) to Self-locking hexagon nuts are used on these
press all parts off the input shaft over the shafts, and these nuts must always be re-
2nd gear wheel. placed in every transmission repair.

35 40 37 Dismantling and assembling input shaft 35-19

Printed In Germany. 20. 19~'~"'-"Ji""'"
35 59 37 Dismantling and assembling output shaft

1
I

1698-35

Note:
No. Designation Qty. Removal Installation

1 Bearing inner race 1 Mark for reinstallation, Do not confuse with inner
press off with suitable race No.3. heat to ap-
separating device (e.g. prox. 120 .C and press
Kukko 15 -17) into place

2 Four-point bearing 1

3 Bearing inner race 1 Mark for reinstallation, Do not confuse with inner
press off with suitable race No.1, heat to ap-
separating device (e.g. prox. 120 .C and press
Kukko 15 -17) into place

4 Cylindrical roller bearing 1 Press off with suitable Heat to approx. 120 .C
separating device (e.g. and press into correct
Kukko 15 -17) position using a suitable
pipe section (e.g.
VW 519)

5 Output shaft 1 Observe matching num-

ber. Readjust if required

35 -21
35 75 19
 Note:
No. Designation Qty. Removal Installation

20 Synchronizing ring 1 i Mark for reinstallation Check for wear.

Fit with the same
gearwheel (Cogs face
driver dogs)

21 Needle cage 1 Mark for reinstallation Fit with the same

gearwheel
22 Hexagon-head bolt 1 Determine installation posi- Tighten to 23 Nm (17 ftlb.
tion of shift fork, measur-
ing from shift rod face to
shift fork stop and record
measurement.

23 Washer 1

24 Inner race 1 Remove, press off across Heat to approx. 120 'C.
guide sleeve if required
and pull off with a suitable
puller.

25 Shift and guide sleeve 1 Engage 4th gear and take Install in correct position.
off carefully complete with The stepped side of the
shift fork. Take care not to shift sleeve faces loose
lose synchromesh com- gearwheel No. 19
Donents.

26 Shift fork (reverse) 1 Adjust so that play at

shift sleeve is barely
noticeable with reverse
engaged. The synchroniz-
ing ring must rotate freely
in neutral position.

27 Fixed gearwheel (5th gear) 1 Identification groove for

fixed gearwheel No. 15

28 Spacer sleeve 1

29 Loose gearwheel 1
(5th gear)

35 -25
.Transmission shafts without recesses for securing the hexagon nuts have been installed since
September 1995.
Self-locking hexagon nuts are used on these shafts, and these nuts must always be replaced
in every transmission repair.
Removal and assembly notes

Removal Installation

1. Remove engine guard and rear underside 1. Tighten hexagon head nuts of drive pinion
panel. and input shaft to specified torque and lock
the nuts.
2. Drain transmission oil.
2. Adjust reverse shift fork to the dimension
3. Remove crossbrace. "A" determined during removal and check
adjustment (refer to explosion drawing
4. Disengage shift rod coupling from inner shift No. 26).
rod.
3. Adjust inner shift rod so that all gears can
5. Support transmission on general-purpose be selected freely without binding. To
transmission jack and unbolt transmission achieve this, undo hexagon-head bolts of
support from body. clamping plate and turn eccentric bushing.

6. Lower engine-transmission assembly only

so far that the assembly will not rest on the
stabilizer bar.

7. Determine installation position of reverse

shift fork for reinstallation, measuring dimen-
sion "A" with depth gauge.

527-34

A = Clamping plate
B = Eccentric bushing

4. Screw a long M 8 bolt into the inner shift

rod and shift through all gears to check
operation.
1791-35
35 Manual Transmission -Gears, Shafts, Internal Controls 911 Carrera (993)

5. Place engine-transmission assembly onto

general-purpose transmission jack and raise
into installation position. Attach transmission
support to body (MA = 46 Nm / 34 ttlb.).

Note
Check engine compartment rubber seal
between body and engine paneling for correct
seating. If required, unbolt transmission sup-
port from body once more, correct seal posi-
tion and refit transmission support.

6. Fit shift rod coupling to inner shift rod.

MA = 18 Nm (13 ftlb.), apply Loctite 270 to
lock.

7. Fill in transmission oil (refer to Vol. I,

page 03-28).
39 09 19 Removing and installing differential

Tools

No. Designation Special tool Order number Explanation

Thrust piece 9252 000.721.925.20

39 -1
 Final Drive, Differential, Differential Lock 911 Carrera (993)

39 09 19 Removing and installing differential

11 1
I
8
,~
1//
If( .:;::.

--1
(
I I
I
I
J
~

(
..,

I
I I
10 7
~

I
~1 , 8
~
... 4 5
6
2

~
911 Carrera (993) Final Drive, Differential, Differential Lock

Note:
No. Designation Qty. Removal Installation

1 Hexagon head bolt 2 Tighten to 44 Nm

(32 ftlb.)
2 Joint flange* 2

3 Hexagon head nut 11 Tighten to 23 Nm

(17ftlb.)
11
1
1 Replace, oil lightly, do
not twist

1 Readjust if required

2 Pack space between

dust and sealing lips
with grease (e.g.
Liqui amoly Pu 53). Use
thrust piece 9252 to
press in until it is seated
against the stop

1 Pull out with suitable inter- Press in with suitable

nal puller (e.g. Kukko 21 -8) thrust piece

10 Bearing outer race 1 Pull out with suitable inter-I Press in with suitable
nal puller (e.g. Kukko 21 -9) thrust piece

11 Transmission housing 1

* The halfshaft flange and seal ring can also be removed and installed with the transmission

installed.

39 -3
39 09 37 Dismantling and assembling differential

Tools
39 09 37

3 4
\

'-/

\
12

5
39 -7
 Final Drive, Differential, Differential Lock 911 Carrera (993)

Dismantling and assembly notes

Note

The small bevel pinions are supported in two 2. Using the centering mandrel, rotate bevel
needle roller sleeves consisting of 31 indivi- pinion relative to housing openings and lift
dual needle rollers each. out carefully, taking care not to lose any
needle rollers.
Dismantling

1. Press out pin with centering mandrel 9289.

540-39

539-39
Assembly

1. Insert differential gears complete with

pressed-in threaded washers across the
large opening in the differential housing and
locate with halfshaft flanges.
 2. Preassemble one bevel pinion with 31 needle 4. Rotate bevel pinion with centering mandrel
rollers, centering mandrel 9289 as well as until the bores in the housing line up with
the spacer sleeve and insert across opening each other.
in the housing.

\-[' ~ /:

~. ~

540-39

541-39

5. Press differential pin into correct position,

3. Complete second bevel pinion with 31 needle take off centering mandrel and lock pin
rollers and push carefully onto centering according to specifications.
mandrel, taking care not to lose any needle
rollers.

Note
To facilitate assembly, apply stiff grease to
place needle rollers into position.

39 -9
~
 39 08 15 Adjusting drive set

Tools

~-!?: ~ ~

J~~~~

3 w
4
'a;~I~~~~~r]~~~~~~~~~~~~~~~:
8
6
(88\ 8(C) 15 14 ~ ~
~
\.!".!J 9
7

Ell ~:).=;~~4~~==
16 10

~Q=:~~:d~klt:=:J::1J;I
,e
~
 39 08 15 Adjusting drive set

Tools

No. Designation Special tool Order number Explanation

1 Measuring mandrel VW 385/1

2 Centering disks 9109 000.721.910.90

3 Master gauge VW 385/30

4 Dial gauge Standard

Dial gauge Standard, measuring

51
range 3 mm

6 Gauge plunger VW 385/14

7 Dial gauge extension VW 385/56 30 mm long'

81 Gauge block plate 9281

9 Dial gauge bracket VW 387

10 Clamping sleeve 9145 000.721.914.50

11 Adjusting device VW 521/4

12 Measuring lever VW 388

13 Gauge plunger VW 388

14 Dial gauge extension VW 382/10 6.0 mm long

15 Dial gauge extension VW 385/15 9.3 mm long

16 Clamping device 9562 000.721.956.20

171 Holder 9253 000.721.925.30

1000.721.928.10
 911 Carrera (993) Final Drive, Differential, Differential Lock

Practical procedure when readjusting the drive set

If it is necessary to adjust drive pinion and ring gear, follow the below sequence to ensure an
efficient working procedure:

1. Determine the total thickness of shims "8tot" (81 plus 82) for the specified preload on the tapered
roller bearings/differential.

2. Determine the thickness of shim "83".

3. Split the total shim thickness "Stot" into S1 and S2 so that the specified circumferential backlash is
present between ring gear and drive pinion.

The aim of this adjustment is to restore the smoothest running position which has been achieved on
test equipment in the production line.

To achieve correct results, greatest possible cleanliness for all assembly work and measuring proce-
dures is essential.

When assembling the final drive assembly. it is only neces~ary to readjust drive pinion and ring gear
or drive set if components have been replaced which have a direct influence on the adjustment.
Refer to the following table to avoid unnecessary adjustment procedures.

~ Drive pinion (83)

Adjust: Ring gear
""""""'-,
(81 + 82)

Replaced component
~I
Transmission case x x

Lateral transmission cover x

Large cylindrical roller bearing and x x

four-point bearing for drive pinion

Drive set x x

Differential housing x

Tapered roller bearing for x

differential

~ 39 -13
 ~~~ ////::~i
f:rn,-"", I
~---~::~~
J
3 -
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--

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~
(/

~
1'1
"".
""
~ ~f'
~
1

~~~~~=-.

1 -Shim S1
2 -Shim S2
3 -Adjusting shim S3
E -Setting value

Correct results may only be achieved if assembly work and measuring procedures are carried out
carefully and with maximum cleanliness.

'?
'/1
~
911 Carrera (993) Final Drive, Differential, Differential Lock

Adjusting drive set

General

The setting of drive pinion and ring gear is a determining factor for the service life and smooth run-
ning of the rear-axle drive. Drive pinions and ring gears that have been checked for good tooth
contact pattem and low noise in both directions of rotation on special test equipment are therefore
matched during prodution. The position at which smoothest running can be achieved is determined
by shifting the drive pinion axially, and embossed on the ring gear as setting value "E".

3 2 1

1 = setting "E" (e.g. 61.43 mm)

2 = circumferential backlash "F"
(e.g. 0.16 mm)
3 = matching number
911 Carrera 4 (993) Final Drive, Differential, Differential Lock

39 08 15 Adjusting drive pinion

Note

The setting value "E" is indicated on the ring

gear.

2018-39

A = Suitable pipe section

5. Set adjusting ring of measuring mandrel

VW 385/1 to dimension "a".
217-39

1 = Setting value "E"

1. Install complete gear set without "83" shims

and tighten all tensioning plate hexagon-
head nuts to 23 Nm (17 ftlb.).

2. Fit gear housing and locate with three nuts.

3. Install and engage sixth gear.

4. Block input shaft with Special Tool 9253

and tighten drive pinion collar nut to 300 Nm
(221 ftlb.).
223-39

a = approx. 65 mm

39 08 15 Adjusting drive pinion 39 -17

Printed in Germany -20, 1997

 Final Drive, Differential, Differential Lock 911 Carrera (993)

6. Assemble measuring mandrel with center- 8. Put gauge block plate 9281 on drive pinion
ing disks 9109, tapered roller bearing, head and insert measuring mandrel into
plunger VW 385 /14 and dial gauge exten- transmission case. Dial gauge extension is
sion VW 385/15. located in the area of the gauge block plate.

7. Set measuring mandrel with master gauge

385/30 to the setting value (61.43 mm in
the example). Set dial gauge (3 mm mea-
suring range) to zero with 1 mm preload.
r~ ~
:'"';;

-, ,
\
~
Jil

544-39

9. Fit lateral transmission cover without a-ring

and tighten crosswise with 4 nuts.

543-39 Note

Do not use a hammer when fitting the lateral

transmission cover (the gauge block plate
held by magnets might falloff). Fit cover in
installation position only by tightening the nuts
uniformly.

~
:~ 39 08 15 Adjusting drive pinion
 911 Carrera (993) Final Drive, Differential, Differential Lock

10. Pull second centering disk with spindle

Example:
towards the outside until the measuring
mandrel can just be turned by hand. If the small painter on the dial gauge is be-
tween 1 and 2 and the large pointer indicates
0.37 mm, then 0.37 mm is the shim thickness
(with 1 mm gauge preload) to be inserted.
l~ Always round up or down to the nearest
0.05 mm (e.g. 0.37 mm to 0.35 mm).

~ 12. After inserting the necessary shims, check

the setting value "E" again. A deviation of
:t 0.03 mm is permissible.

[7
545-39

11. Turn measuring mandrel carefully until the

dial gauge extension is vertical to the face
of the drive pinion head. At this point, the
pointer of the dial gauge reaches maxi-
mum deflection (reverse point) and the dial
gauge must be read.

Note
The measured value always deviates from the
set dimension clockwise (the smaller pointer
on the dial gauge is between 1 and 2), i.e. if
the dial gauge is set with a preload of 1 mm,
the value deviating from 1 is taken as shim
thickness "S3",

39 -19
~
 Final Drive, Differential, Differential Lock 911 Carrera (993)

Adjusting ring gear

Determine total shim thickness "5 tot." 6. Fasten universal dial gauge holder VW 387
(51 + 52). with dial gauge and extension to the case
and set to a with 2 mm preload.
The ring gear must be adjusted, if the:

transmission case,
lateral transmission cover,
tapered roller bearing for differential,
differential housing or drive set
have been replaced.

Note

The drive pinion must be removed to deter-

mine the preload of the differential tapered
roller bearings.

1. Make sure that the bearing outer races of

the tapered roller bearings are well seated 546-39

in the transmission case or lateral transmis-

A = Dial gauge extension (approx. 30 to 40 mm
sion cover, respectively.
long)
2. Fit one spacer ring (2.5 mm thick) on the B = Gauge block plate VW 385/17
ring gear side and on the opposite side of
the differential to be used.
7. Move differential up and down. Read off
backlash on the dial gaug and note.
3. Insert differential into transmission case and
Note
rotate several times.
Do not turn differential while measuring back-
4. Fit lateral transmission cover without seal lash as this will give an incorrect reading.
and tighten all hexagon-head nuts to 23 Nm
(17 ftlb.). 8. Calculate "S tot.".
"S tot." = Fitted shim thickness
5. Put gauge block plate VW 385/17 on the + Measured value
collar of the differential. + Pressure fit of tapered roller bearing
911 Carrera (993) Final Drive, Differential, Differential Lock

Example The calculated shim thicknesses must be

rounded up or down for plausible dimensions
Thickness of shims inserted 5.00 mm that will not alter the total thickness 81 and 82.
Measured value 0.75 mm
Pressing (constant value) 0.40 mm Example:
"S tot." 6.15 mm
Calculated thicknesses

9. Remove differential, pull off both tapered

81 + 82 = 2.375 + 3.775 = 6.15 mm
roller bearings and split calculated shim
thickness "5 tot." as follows.
5elcect spacer 51 0.70 mm thinner and 52
0.70 mm thicker as a starting point for sub- Rounded thicknesses
sequent adjustment of the backlash.
51 + 52 = 2.35 + 3.80 = 6.15 mm

Example Measure shims with a micrometer in several

Total shim thickness of spacers places. Permissible deviation 0.02 mm. Also
51 + 52 = 6.15 mm check shims for burrs and damage.

Thickness of spacer 81

6.15 mm = 3.075 mm
2 -0.700 mm
2.375 mm

Thickness of spacer 82

6.15 mm = 3.075 mm
2 + 0.700 mm
3.775 mm

Note

Spacers are available in thicknesses of 1.6 to

3.1 mm in increments of 0.10 mm.

By using a 0.25 mm shim, the shim thick-

nesses may be graduated in increments of
0.05 mm.
Adjusting circumferential backlash

Note
The backlash to be set is embossed on the
7. Fit universal dial gauge holder with flat
ring gear. extension in such a way as to produce a
right angle between dial gauge axis and
1. Mount gear set using shims "53" deter-
lever.
mined while adjusting the drive pinion.

Note

Make sure that the collar nut of the drive pi-

nion is tightened to 300 Nm (221 ftlb.) before
measuring backlash.

2. Insert differential with tapered roller bearing

and shims (51 + 52) into the housing.

3. Fit lateral transmission cover and tighten all

hexagon-head nuts to 23 Nm (17 ftlb.).

Note

Always make sure that there is a certain 548-39

amount of backlash when tightening the nuts.

Never allow the drive pinion to seize. Dimension "a" = approx. 80 mm

4. Assemble measuring lever VW 388 and 8. Turn ring gear carefully at the clamping
adjusting device VW 521/4 and adjust lever screw of the adjusting device as far as the
length to 80 mm with the plunger. Refer to stop and set the dial gauge to zero. Turn
dimension "a" in the picture. back ring gear and read off circumferential
backlash. Note down the reading.
5. Insert adjusting device with clamping sleeve
(Special Tool 9145) into the differential and
clamp firmly.

6. Rotate differential in both directions several

times to settle the tapered roller bearings.

39 08 15 Adjusting drive pinion

911 Carrera 4 (993) Final Drive, Differential, Differential Lock

Note

When carrying out measurements, the drive pi-

nion must be blocked with Special Tool 9562.

"'(( I --
y

1710-39

9. After turning the ring gear a further 90°, re-

peat measuring procedures three times.
The measured values must not deviate from
one another by more than 0.03 mm.

Note
The backlash to be adjusted is embossed on
the ring gear. A deviation of
:t 0.03 mm is permissible

10. If the required backlash cannot be ob-

tained, replace spacers (51 + 52) again.
The total shim thickness ("5 tot.") must not
be altered, however.