® AfterSales Training Drivetrain Repair – Sports Cars 911 Carrera/S/4/4S 6-Speed Manual Transmission P30A Porsche AfterSales Training Student Name: Training Center Location: Instructor Name: Date: _ Important Notice: Some of the contents of this AfterSales Training brochure was originally written by Porsche AG for its restof-world English speaking market The electronic text and graphic files were then imported by Porsche Cars N.A, Inc and edited for content Some equipment and technical data listed in this publication may not be applicable for our market Specifications are subject to change without notice We have attempted to render the text within this publication to American English as best as we could We reserve the right to make changes without notice © 2010 Porsche Cars North America, Inc All Rights Reserved Reproduction or translation in whole or in part is not permitted without written authorization from publisher AfterSales Training Publications Dr Ing h.c F Porsche AG is the owner of numerous trademarks, both registered and unregistered, including without limitation the Porsche Crest®, Porsche®, Boxster®, Carrera®, Cayenne®, Cayman™, Panamera®, Tiptronic®, VarioCam®, PCM®, 911®, 4S®, FOUR, UNCOMPROMISED.SM and the model numbers and distinctive shapes of Porsche's automobiles such as, the federally registered 911 and Boxster automobiles The third party trademarks contained herein are the properties of their respective owners Specifications, performance standards, options, and other elements shown are subject to change without notice Some vehicles may be shown with non-U.S equipment Porsche recommends seat belt usage and observance of traffic laws at all times Printed in the USA Part Number - PNA P30 A01 Edition - 3/10 Table of Contents Description Section Transmission Type Designations 911 Carrera (997) 6-Speed Transmission Notes & Conversion Charts Drivetrain Repair – 911 (997) 6-Speed Drivetrain Repair – 911 (997) 6-Speed Transmission Type Designations Transmission Number Identification Digit: 10 11 Example: G 0 Transmission Type: Transmission Version: Index of Variants: Serial Number: 911, Boxster and Cayman Transmission Type Designations Since Model Year 1989 Model Year Transmission Type Technical Data Installed In 1989 G50.00 G50.01 G50.02 G50.50 G64.00 G64.01 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 911 Carrera - RoW 911 Carrera - USA, Australia, Japan 911 Carrera - Switzerland 911 Turbo - World-Wide 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - Switzerland 1990 A50.01 G50.03 G50.04 G64.00 G64.01 4-Speed A/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - Switzerland 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - Switzerland 1991 A50.01 G50.03 G50.04 G50.52 G64.00 G64.01 4-Speed A/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - Switzerland 911 Turbo (964) - World-Wide 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - Switzerland 1992 A50.02 A50.03 G50.03 G50.04 G50.05 G50.10 G50.52 G64.00 G64.01 G64.02 4-Speed A/T 4-Speed A/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 911 Carrera (964) - RoW 911 Carrera (964) - USA/Canada 911 Carrera (964) - RoW 911 Carrera (964) - Switzerland 911 Carrera (964) - USA/Canada 911 Carrera RS (964) - RoW 911 Turbo (964) - World-Wide 911 Carrera (964) - RoW, USA/Canada 911 Carrera (964) - Switzerland 911 Carrera (964) - Taiwan Drivetrain Repair – 911 (997) 6-Speed Page 1.1 Transmission Type Designations Model Year Transmission Type Technical Data 1993 A50.02 A50.03 G50.03 G50.04 G50.05 G50.10 G64.00 G64.01 G64.02 4-Speed A/T 4-Speed A/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 911 Carrera (964) - RoW 911 Carrera (964) - USA/Canada, Taiwan 911 Carrera (964) - RoW 911 Carrera (964) - Switzerland/Taiwan 911 Carrera (964) - USA/Canada 911 Carrera RS (964) - RoW 911 Carrera (964) - RoW, USA 911 Carrera (964) - Switzerland 911 Carrera (964) - Taiwan 1994 A50.02 A50.03 G50.03 G50.04 G50.05 G50.10 G50.52 G64.00 G64.01 G64.02 4-Speed A/T 4-Speed A/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 5-Speed M/T 911 Carrera (964) - RoW 911 Carrera (964) - USA/Canada, Taiwan 911 Carrera (964) - RoW 911 Carrera (964) - Switzerland/Taiwan 911 Carrera (964) - USA/Canada 911 Carrera RS (964) - RoW 911 Turbo 3.6 (964) - World-Wide 911 Carrera (964) - RoW, USA 911 Carrera (964) - Switzerland 911 Carrera (964) - Taiwan 1995 A50.04 A50.05 G50.20 G50.21 4-Speed A/T 4-Speed A/T 6-Speed M/T 6-Speed M/T 911 Carrera (993) - RoW 911 Carrera (993) - USA/Canada, Taiwan 911 Carrera (993) - USA/Canada 911 Carrera (993) - RoW 1996 A50.04 A50.05 G50.20 G50.21 G64.20 G64.21 G64.51 4-Speed A/T 4-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 911 Carrera (993) - RoW 911 Carrera (993) - USA/Canada, Taiwan 911 Carrera (993) - USA/Canada 911 Carrera (993) - RoW 911 Carrera (993) - USA/Canada 911 Carrera (993) - RoW 911 Turbo (993) - World-Wide 1997 A50.04 A50.05 G50.20 G64.20 G64.51 A86.00 G86.00 4-Speed A/T 4-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed M/T 911 Carrera (993) - RoW 911 Carrera (993) - USA/Canada, Taiwan 911 Carrera (993) - RoW, USA/Canada 911 Carrera (993) - RoW, USA/Canada 911 Turbo (993) - World-Wide Boxster (986) Boxster (986) 1998 A50.04 A50.05 G50.20 G64.20 G64.42 G64.51 A86.00 G86.00 4-Speed A/T 4-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed M/T 911 Carrera (993) - RoW 911 Carrera (993) - USA/Canada, Taiwan 911 Carrera (993) - RoW, USA/Canada 911 Carrera 4/4S (993) - RoW, USA/Canada 911 Turbo (993) - Taiwan 911 Turbo (993) - RoW, USA/Canada Boxster (986) Boxster (986) Page 1.2 Installed In Drivetrain Repair – 911 (997) 6-Speed Transmission Type Designations Model Year Transmission Type Technical Data Installed In 1999 A86.00 G86.00 A96.00 A96.30 G96.00 G96.30 5-Speed A/T 5-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T Boxster (986) Boxster (986) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 2000 A86.05 A86.20 G86.01 G86.20 A96.00 A96.30 G96.00 G96.30 G96.90 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T Boxster (986) Boxster S (986) Boxster (986) Boxster S (986) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 GT3 (996) - RoW 2001 A86.05 A86.20 G86.01 G86.20 A96.00 A96.30 G96.00 G96.30 G96.50 A96.50 G96.88 G96.90 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T Boxster (986) Boxster S (986) Boxster (986) Boxster S (986) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Turbo (996) - World-Wide 911 Turbo (996) - World-Wide 911 GT2 (996) - World-Wide 911 GT3 (996) - RoW 2002 A86.05 A86.20 G86.01 G86.20 A96.10 A96.35 G96.01 G96.31 G96.50 A96.50 G96.88 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T Boxster (986) Boxster S (986) Boxster (986) Boxster S (986) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Turbo (996) - World-Wide 911 Turbo (996) - World-Wide 911 GT2 (996) - World-Wide Drivetrain Repair – 911 (997) 6-Speed Page 1.3 Transmission Type Designations Model Year Transmission Type Technical Data 2003 A86.05 A86.20 G86.01 G86.20 A96.10 A96.35 G96.01 G96.31 G96.50 A96.50 G96.88 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T Boxster (986) Boxster S (986) Boxster (986) Boxster S (986) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Turbo (996) - World-Wide 911 Turbo (996) - World-Wide 911 GT2 (996) - World-Wide 2004 A86.05 A86.20 G86.01 G86.20 A96.10 A96.35 G96.01 G96.31 G96.50 A96.50 G96.88 G96.96 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T Boxster (986) Boxster S (986) Boxster (986) Boxster S (986) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Turbo (996) - World-Wide 911 Turbo (996) - World-Wide 911 GT2 (996) - World-Wide 911 GT3 (996) - USA/Canada 2005 A87.01 A87.20 G87.01 G87.20 A96.10 A96.35 G96.01 G96.31 A97.01 G97.01 G96.50 A96.50 G96.88 G96.96 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T Boxster (987) Boxster S (987) Boxster (987) Boxster S (987) 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera (996) - RoW, USA/Canada 911 Carrera/S (997) - RoW, USA/Canada 911 Carrera/S (997) - RoW, USA/Canada 911 Turbo (996) - World-Wide 911 Turbo (996) - World-Wide 911 GT2 (996) - World-Wide 911 GT3 (996) - USA/Canada 2006 A87.01 A87.20 G87.01 G87.20 A87.21 G87.21 A97.01 G97.01 A97.31 G97.31 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 5-Speed A/T 6-Speed M/T Boxster (987) Boxster S (987) Boxster (987) Boxster S (987) Cayman S (987) Cayman S (987) 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada Page 1.4 Installed In Drivetrain Repair – 911 (997) 6-Speed Transmission Type Designations Model Year Transmission Type Technical Data Installed In 2007 A87.02 A87.21 G87.01 G87.21 A87.02 A87.21 G87.01 G87.21 A97.01 G97.01 A97.31 G97.31 G97.50 A97.50 G97.90 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T Boxster (987) Boxster S (987) Boxster (987) Boxster S (987) Cayman (987) Cayman S (987) Cayman (987) Cayman S (987) 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Turbo (997) - World-Wide 911 Turbo (997) - World-Wide 911 GT3 (997) - USA/Canada 2008 A87.02 A87.21 G87.01 G87.21 A87.02 A87.21 G87.01 G87.21 A97.01 G97.01 A97.31 G97.31 G97.50 A97.50 G97.88 G97.90 5-Speed A/T 5-Speed A/T 5-Speed M/T 6-Speed M/T 5-Speed A/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T 6-Speed M/T Boxster (987) Boxster S (987) Boxster (987) Boxster S (987) Cayman (987) Cayman S (987) Cayman (987) Cayman S (987) 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Turbo (997) - World-Wide 911 Turbo (997) - World-Wide 911 GT2 (997) - World-Wide 911 GT3 (997) - USA/Canada 2009 CG2.00 CG2.20 G87.10 G87.40 CG2.00 CG2.20 G87.10 G87.40 CG1.00 G97.05 CG1.30 G97.35 G97.50 A97.50 G97.88 7-Speed PDK 7-Speed PDK 6-Speed M/T 6-Speed M/T 7-Speed PDK 7-Speed PDK 6-Speed M/T 6-Speed M/T 7-Speed PDK 6-Speed M/T 7-Speed PDK 6-Speed M/T 6-Speed M/T 5-Speed A/T 6-Speed M/T Boxster (987) Boxster S (987) Boxster (987) Boxster S (987) Cayman (987) Cayman S (987) Cayman (987) Cayman S (987) 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Turbo (997) - World-Wide 911 Turbo (997) - World-Wide 911 GT2 (997) - World-Wide Drivetrain Repair – 911 (997) 6-Speed Page 1.5 Transmission Type Designations Model Year Transmission Type Technical Data 2010 CG2.00 CG2.20 G87.10 G87.40 CG2.00 CG2.20 G87.10 G87.40 CG1.00 G97.05 CG1.30 G97.35 G97.55 CG1.50 G97.90 7-Speed PDK 7-Speed PDK 6-Speed M/T 6-Speed M/T 7-Speed PDK 7-Speed PDK 6-Speed M/T 6-Speed M/T 7-Speed PDK 6-Speed M/T 7-Speed PDK 6-Speed M/T 6-Speed M/T 7-Speed PDK 6-Speed M/T Page 1.6 Installed In Boxster (987) Boxster S (987) Boxster (987) Boxster S (987) Cayman (987) Cayman S (987) Cayman (987) Cayman S (987) 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 2/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Carrera 4/S (997) - RoW, USA/Canada 911 Turbo (997) - World-Wide 911 Turbo (997) - World-Wide 911 GT3 (997) - World-Wide Drivetrain Repair – 911 (997) 6-Speed 911 Carrera (997) Transmission Gear Ratio as of 2009 Model (G97.05 and G97.35) Shift Mechanism – Cable shifting The gear ratio for the 3rd gear has been changed to 1.56 for all manual transmissions for the 911 Carrera 2009 model Gear Ratio Graph Note! The transmission diagram indicates general reference values based on a mean effective rolling radius The stated values not take account of deviations due to tire tolerances, changes in the rolling radius, wear and tire slip Notes: Similar with other Porsche vehicles, cable shifting is also used on the 911 Carrera This prevents the transfer of engine movements and vibration to the gearshift lever In contrast to the previously employed shift linkage, shift and selector cables (which are able to withstand tension and pressure) form the connection between gearshift lever and transmission The advantages of this system are reduced space requirements, low weight and above all the effective prevention of the transfer of engine movements or vibration to the gearshift lever, without impairing shifting precision The repositioning of the deflection point at the gearshift lever has enabled the 911 Carrera to achieve shorter shift travel, reduced by approx 15%, while maintaining the same required shifting forces (see Synchronization) Furthermore, play in the shift module under the gearshift lever has been reduced, resulting in a more precise gearshifting gate A – Outer shift lever to engage gear B – Selector lever shaft to preselect gear The selector cable is connected to the selector lever shaft (B) for preselecting the gear The shift cable is connected to the outer shift lever (A) for engaging the gear Page 2.4 Drivetrain Repair – 911 (997) 6-Speed 911 Carrera (997) Transmission Shift Module Input Shaft The fixed gear wheels for reverse gear, 1st gear and 2nd gear are fixed parts of the input shaft The gear wheels for 3rd to 6th gear are designed as loose gear wheels All loose gear wheels are mounted using one-piece or twopiece needle-roller bearings The needle-roller bearings are constructed in various thicknesses (roller diameters) to compensate for wheel and shaft tolerances The correct needle-roller bearing size must be determined when fitting a new input shaft or new loose gear wheels (see Workshop Manual) - Gear-shift lever - Shift cable - Outer shift lever - Inner shift lever - Central catch - Inner shift/selector lever - Gearshift rod catch - Shift fork Transmission Housing The transmission housing consists of two parts which are made from a light metal alloy In order to ensure direct air heat exchange, the surface of the housing is provided with cooling fins Cooling is supported by effective air guidance with defined air intake at the front underbody panelling - Input shaft - Two-piece needle-roller bearing - 6th gear - 5th gear - Two-piece needle-roller bearing - 4th gear 7, - One-piece needle-roller bearing - 3rd gear The input shaft is hollow in order to reduce weight and for lubrication purposes The input shaft is provided with cross bores (see arrows) for lubricating the loose gear wheel bearings Gear Wheel Set The transmission is designed as a two-shaft transmission with overhead input shaft and hypoid ring gear and pinion shaft The loose and fixed gear wheels for all forward gears are ground and honed for the purposes of noise reduction Pairing of the gear wheels was not necessary Drivetrain Repair – 911 (997) 6-Speed Page 2.5 911 Carrera (997) Transmission Drive Shaft Reverse Gear The gear wheels for 1st and 2nd gear are designed as loose gear wheels The loose gear wheels are mounted using one-piece needle-roller bearings The needle-roller bearings are constructed in various thicknesses (roller diameters) to compensate for wheel and shaft tolerances The correct needle-roller bearing size must be determined when fitting a new drive shaft or new loose gear wheels (see Workshop Manual) The reverse gear is located in the gear housing The intermediate gear wheel (8) for the reverse gear is mounted on a pin by way of needle-roller bearings and secured using the bearing segment (9) The pin is inserted in the transmission housing and is supported on the gear housing by means of the bearing segment (9) The bearing segment is held and secured by way of a screw, which is screwed in from the gear housing The reverse gear is synchronized and can therefore also be engaged when the vehicle is rolling slowly - Needle-roller bearing - 1st gear - Reverse gear - 2nd gear - Needle-roller bearing - 4th gear - 3rd gear - 6th gear - 5th gear The drive shaft is hollow in order to reduce weight and to provide for lubrication at the bearing points The drive shaft is provided with cross bores for lubricating the loose gear wheel bearings and the taper roller bearing Page 2.6 Drivetrain Repair – 911 (997) 6-Speed 911 Carrera (997) Transmission Gear Wheels Notes: In order to reduce weight, the fixed gear wheels for 3rd and 4th gear are provided with bores and their loose gear wheels are provided with recesses in the clutch hub Ring and Pinion The ring gear and pinion shaft is designed as a hypoid drive This means that the center is positioned 10 mm above the center axis of the drive shaft Hypoid drives with the same crown wheel size as other drive types can transfer higher torques due to the sturdier construction of the teeth of the drive shaft In addition, the altered crown wheel position can be utilised to decrease deflection angles at the drive shafts The drive shaft is hollow in order to reduce weight and supply lubricating oil to the bearings There are no design dimensions or adjustment values specified on the crown wheel or bevel gear The actual position of the drive shaft and the tooth backlash must be measured before disassembling, if possible If an actual measurement is not possible, the transmission must be replaced Drivetrain Repair – 911 (997) 6-Speed Page 2.7 911 Carrera (997) Transmission Synchronization Synchronization of 3rd and 4th Gear The synchronization is designed as triple synchronization for 1st and 2nd gear, as double synchronization for 3rd gear and as single synchronization for 4th, 5th and 6th gear The synchronizer rings are made from steel or brass and are carbon coated for 1st, 2nd and 3rd gear 3rd gear is provided with double synchronization and the two friction surfaces are carbon coated 4th gear is located on the opposite side This is provided with single synchronization with a brass synchronizer ring Synchronization of 1st and 2nd Gear As the loose gear wheels for 1st and 2nd gear have a high mass because of the gear ratio and at the same time a short shifter needs to be implemented, triple synchronization is used for these gears With this type of synchronization there are three friction surfaces available for the synchronization process These friction surfaces are carbon coated to minimize wear The synchronizer rings are made of steel to ensure that synchronization is not impaired if the transmission becomes hot - Cone ring - Synchronization ring - Friction ring, double-coated - Gearwheel - Shift collar - Synchronizer body - Friction ring, single-coated - Synchronization ring, molybdenum-coated Note! – Cone ring – Synchronizer ring – Double-coated friction ring – Gear wheel – Shift collar As of December 2005 these synchronizer rings are also carbon coated Notes: Page 2.8 Drivetrain Repair – 911 (997) 6-Speed 911 Carrera (997) Transmission Synchronization of 5th and 6th Gear Gear Set Shell 5th and 6th gear are also designed with single synchronization, with the synchronizer rings being made from brass and, since model year 2007, carbon coated – Oil collecting pan - Shift collar - Synchronizer body - Friction ring, single-coated - Synchronization ring, molybdenum-coated Synchronization of Reverse Gear The reverse gear is also provided with single-cone synchronization – Shift rods – Gear set shell – Shift finger for reverse gear An aluminum gear set shell produced using thin-wall casting is used in these transmissions to minimize the oil churning and friction losses and thus increase efficiency However, as this impairs lubrication, this shell-like casing is also used to collect oil and direct it to lubrication points The shift rods are also partly mounted in the gear set shell – Gear wheel – Shift collar – Synchronizer ring Drivetrain Repair – 911 (997) 6-Speed Page 2.9 911 Carrera (997) Transmission L1 - Taper roller bearing L2 - Cylindrical-roller bearing L3 - Four-point bearing L4 - Cylindrical-roller bearing L5 - Needle-roller bearing Lubrication Bearings The output shaft is mounted using a double-taper roller bearing (L1) and a cylindrical-roller bearing (L2) The input shaft is mounted radially and axially in the gear housing by means of a four-point ball bearing and is also radially mounted in the transmission housing with a roller bearing and a needle-roller bearing (L4 and L5) Information! Oil quantity 3.1 qts (2.9 liters), oil change quantity 2.8 qts (2.6 liters) Only transmission oil approved by Porsche is to be used Oil collecting pans and oil baffles are fitted in the transmission to ensure optimum lubrication of the loose gear bearings, the reverse gear wheel bearing and the drive-shaft bearing These oil collecting pans collect oil that is thrown up by the crown wheel and direct it to the corresponding lubrication points A bore is provided in one of these oil baffles (see arrow) From there, oil drips back into a collecting pan below and is supplied to the reverse gear double wheel bearing Page 2.10 Drivetrain Repair – 911 (997) 6-Speed 911 Carrera (997) Transmission Function Limited-slip Differential Certain 911 Carrera (997) vehicles are equipped with a mechanical limited-slip differential Thanks to the rear engine design and the resulting distribution of weight, these vehicles, which are also equipped with PSM, are well designed for converting engine power into propulsion (good traction) even under poor, e.g wet, road conditions Consequently, a limited-slip differential of 22% is adequate under traction Higher locking factors would have a negative effect on the vehicle’s cornering performance without making any substantial improvement to the traction characteristics In deceleration, the locking factor is 27% This value has been selected to be greater than the locking value under traction as this configuration stabilizes the vehicle against oversteering in the event of load changes during cornering The limited-slip differential was configured as part of the overall vehicle dynamics configuration and the locking value should therefore not be changed The housing of the limited-slip differential (1) is driven by the crown wheel of the ring gear and pinion shaft The pressure pieces (3) and (7) are interlocked with the housing (1), but can move axially and are moved to the left and right toward the disc packs when loaded by the differential pins (2) The resulting expansion force (Pax) depends on the torque applied, the fleet angles (α) and the pressure pieces (3) and (7) The greater the expansion forces Pax acting axially on the friction discs, the higher the locking value of the multipledisc limited-slip differential Preloading via the cup springs (6) in both disc packs enables the limited-slip differential to be functional even when no torque is applied During driving, the static friction torque due to preloading of the disc packs is significantly increased by the expansion force, which also acts on the disc packs Notes: Drivetrain Repair – 911 (997) 6-Speed Page 2.11 Notes Page 2.12 Drivetrain Repair – 911 (997) 6-Speed Notes Drivetrain Repair – 911 (997) 6-Speed Page 3.1 Notes Page 3.2 Drivetrain Repair – 911 (997) 6-Speed Notes Drivetrain Repair – 911 (997) 6-Speed Page 3.3 Conversion Charts Temperature Conversion Metric Conversion Formulas INCH X MM X MILE X KM (KILOMETER) X OUNCE X GRAM X POUND (lb) X kg (KILOGRAM) X CUBIC INCH X cc (CUBIC CENTIMETER) X LITERS X CUBIC FEET (cu.ft.) X CUBIC METERS X FOOTPOUND(ft lb) X Nm (NEWTON METER) X HORSEPOWER (SAE) X HORSEPOWER (DIN) X Kw (KILOWATT) X HORSEPOWER (SAE) X MPG (MILES PER GALLON) X BAR X PSI (POUND SQUARE INCH) X GALLON X LITER X FAHRENHEIT CELSIUS X Page 3.4 25.4 0394 1.609 621 28.35 0352 454 2.2046 16.387 061 0353 28.317 35.315 1.3558 7376 746 9861 1.34 1.014 4251 14.5 0689 3.7854 2642 32÷1.8 1.8+32 = = = = = = = = = = = = = = = = = = = = = = = = = = Drivetrain Repair – 911 (997) 6-Speed MM INCH KILOMETER (KM) MILE GRAM OUNCE KILOGRAM (kg) lb (POUND) CUBIC CENTIMETER (cc) CUBIC INCH CUBIC FEET (cu.ft.) LITERS CUBIC FEET (cu.ft.) NEWTON METER (Nm) ft lb (FOOT POUND) KILOWATT (Kw) HORSEPOWER (SAE) HORSEPOWER (SAE) HORSEPOWER (DIN) Km/l (KILOMETER PER LITER) POUND/SQ INCH (PSI) BAR LITER GALLON CELSIUS FAHRENHEIT Part Number - PNA P30 A01 ... Notes: Drivetrain Repair – 911 (997) 6-Speed Page 2.11 Notes Page 2.12 Drivetrain Repair – 911 (997) 6-Speed Notes Drivetrain Repair – 911 (997) 6-Speed Page 3.1 Notes Page 3.2 Drivetrain Repair. .. 911 Carrera (964) - RoW 911 Carrera (964) - USA/Canada, Taiwan 911 Carrera (964) - RoW 911 Carrera (964) - Switzerland/Taiwan 911 Carrera (964) - USA/Canada 911 Carrera RS (964) - RoW 911 Carrera... M/T 5-Speed M/T 911 Carrera (964) - RoW 911 Carrera (964) - USA/Canada, Taiwan 911 Carrera (964) - RoW 911 Carrera (964) - Switzerland/Taiwan 911 Carrera (964) - USA/Canada 911 Carrera RS (964)