Workshop l Manual DR. ING. h. c. F. PORSCHE Aktiengesellschaft The Workshop Manual is only for the internal use of the Porsche Dealer Organization. @ 1977 Dr. Ing. h.c. F. Porsche Aktiengesellschaft Sales, D-7140 Ludwigsburg All rights resewed - Printed in Germany XX, 1986 WKD 481 621 Print No. W 42-608-126-l List of Repair Groups General RepairGroups Maintenance, Self-diagnosis Technical Data Paae 0.1 Group 03 10 13 15 17 19 Engine Engine, Crankcase Engine, Crankshaft, Pistons Engine, Cylinder Head and Valve Drive Engine, Lubrication Engine, Cooling Fuel Supply Air Flow Controlled Fuel injection Exhaust System/Emission Contrds Starter, Power Supply, Cruise Control Ignition System Clutch, Controls Torque Converter Manual Transmission, Controls, Case Manual Transmission, Gears, Shafts Automatic Transmission, Controls, Case Automatic Transmission, Gears, Valve Body Differential, Transaxle System Front Wheel Suspension Rear Wheel Suspension, Axle Shaft Wheels, Tires, Alignment Antiblock System Brakes, Mechanical Brakes, Hydraulics Steering Body-Front Section Body-Center Section Body-Rear Section Lids Doors Hardtop Bumpers Glasses, Window Control Exterior Equipment Interior Equipment Seats Seat Covers 20 24 26 27 28 30 Transmission 32 34 35 37 38 39 40 Chassis 42 44 45 46 47 48 50 51 53 55 57 61 63 64 66 68 72 74 80 85 Heating, Ventilation, Air Condition Electrics Heater Ventilation Air Conditioner Instruments, Fuel Gauge, Alarm System Radio Windshield Wipers and Washer Exterior Lights, Lamps, Switches Interior Lights Wiring 87 90 91 92 94 96 97 Printed in Germany - XX, 1997 928 a Table of contents Volume III Page General Data Technical data Tightening torques 30-0101 30-0105 Torque Converter Removing and installing torque convener Removing and installing selector lever cover frame Removing and installing selector lever cable Adjusting selector lever cable Removing and installing starter locking and backup light switch Adjusting starter locking and backup light switch Checking adjustment of selector lever cable and starter locking / backup light switch Bowden cable for control pressure, removing and installing (service solution) Bowden cable for control pressure, adjusting Removing and installing transmission Adjusting transmission suspension Disassembling and assembling front convener housing Disassembling and assembling front converter housing (`87 models onward) Removing and installing rear transmission case Removing and installing rear transmission Disassembling and assembling transmission 32-101 37-101 37-103 37-105 37-107 37-109 37-l 11 37-113 37-115 37-l 17 37-123 37-125 37-l 30 37-131 37.135 37-143 Transmission I Gears, Valve Body 38-101 38-l 10 38-11 Oa 38-111 38-123 38-l 25 38-130a 38-131 38-133 38-137 38-141 38-143 38-145 38-147 Checking transmission operation .................... Checking operation ........................... Checking operation (87 models onward) ................ ............................ Troubleshooting. Removing and installing shift valve casing ............... Disassembling and assembling shift valve housing .......... Disassembling and assembling shift valve casing (`87 models onward) Removing and installing lower cover .................. Disassembling and assembling lower cover .............. Replacing ATF and filter ........................ Flushing ATF cooler and lines ..................... Removing and installing governor ................... Checking governor ........................... Removing and installing vacuum modulator .............. Removing and installing primary pump. ................ 38-149 - Table of contents Prlnwd in Germany- XXXV, 1999 1 Volume III Table of contents 929 Disassembling Disassembling Disassembling Disassembling Disassembling and and and and and assembling assembling assembling assembling assembling secondaty pump ............... gear assembly ................ one-way clutch ................ clutch K 1 .................. clutch K 2 .................. 38-l 55 38-l 57 38-163 36-l 69 38-177 Differential I Transaxle system Removing and installing final drive ...................... Disassembling and assembling final drive .................. Disassembling and assembling differential .................. Disassembling and assembling bearing assembly .............. Disassembling and assembling bearing assembly / Determining shims for bearing assembly .......................... Adjusting drive pinion and ring gear. ..................... Adjusting drive pinion and ring gear. ..................... Adjusting drive pinion and ring gear. ..................... Adjusting drive pinion and ring gear. ..................... Adjusting drive pinion and ring gear. ..................... Adjusting drive pinion and ring gear. ..................... Disassembling and assembling central tube ................. Checking central tube ............................. PSD-Diagnosis I Troubleshooting ....................... 39-l 01 39-107 39-113 39-l 19 thickness of 39-123 39-125 39-127 39-128 39-130 39-133 39-135 39-137 39-139 D39-201 l 2 Printed Table of contents In Genany - XXXV. 1999 928 4 - SPEED AUTOMATIC TRANSMISSION (UP TO '86 MODELS) General Data 30 a a 1 - Front 3 - Final converter drive casing 2 - Automatic transmission Transmission A 28.01 A 28.02 Type installed in / '83 and '84 models / rest for of Japan the 928 S, USA series 928 S, Special world, option for '84 models Europe A 28.03 928 S, Special option (M 251) Europe / rest of the world 3/84 onward (as 28.02, but rear axle transmission ratio 13 : 33) 928 S, USA series 928 S, Special rest of / '85 models / for '85 Japan models A 28.04 A 28.05 option Europe the world 0 A 28.06 928 S, Special option (M 251) Europe / '85 models rest of the world (as A 28.05, but with rear axle transmission ratio 13 : 33) 928 S, USA series 928 S, Special rest of / '86 models / for '86 Japan models A 28.07 A 28.08 option Europe the world A 28.09 928 S, Special option (M 251) Europe / '86 models rest of the world (as A 28/08, but with rear axle transmission ratio (13 : 33) 928 S, Australia series, special option (M 299) for FGR, Switzerland, Austria, Sweden ('86 models) A 28.11 0 Printed in Germany-XX,1988 Technical Data 30 - 0101 30 Technical Data 4-speed automatic transmlsslon General Data 920 0 (`87 models onward) 1 - Front converter casing 3 - Final drive 2 - Automatic transmission Type A28.12 A28.14 A28.16 A28.18 Key-number - Equipment Installed In 928 S 4 USNJap. 928 S 4 R.d.W. 928 S 4 worldwide 928 GTS worldwide model 87188 87188 89/90/91 92/93 a 30 - 0102 Printed Technical Data in Germany - XXXI, 1993 928 a General Data 30 Technical Data Tmsmlsslon 1 DeslgnatTon A 28 02 T 12 1 -r 6 E 05065 [ - @zFc,985 1 = 5 - speed transmission 6 = Automatic Transmission for 8 cylinder vehicles Limited-slip differential 40 % Country code Transmission type A 28 = four speed automatic A 22 = three-speed automatic G 28 = five-speed manual transmission 72227012 01 722 270 14 01 7222701701 722 270 18 01 722 270 21 01 722316 02.~ A28.01 722 318 02...= A 28.02/03 72231602...= A28.04 722 318 02...= A 28.0.5/06 722 318 02...= A 28.08/09 7222702501 7222702601 722 270 21 01 7222703201 7222703401 72231602...= 72231602.~ A28.07 A28.11 722 326 02...= A 28.12/14 72236003...= A28.16 72236003...= A28.18 Technlcal Printed Data - XXXI, 1993 30 - 0102a in Germany 30 Technical Data Transmlssion General Data 928 numbers (12 dlglts) A2814 T Index for varlants wlthln the assembly number 0 = no differential 1 = normal differential 2 = ZF limited slip differential 3 = proportional slip differential Model year J = 1988 K = 1989 L = 1990 M = 1991 Serlal number e.g. 00903 Note: As from model `88. the gear box number will be readable from below, stamped on the rear stiffening rib of the rear-axle housing * As of MY `92, the model letter is omitted. 30 - 0102b Technical Data Printed in Germany - XXXI. 1993 a 928 30 General data A28.0 1/04/07/l 2 R8.02/03/05/06/08/09/11/14/16/18 m A 28/t 6 Fully automatic 4-speed sun-an&planet transmis Ratios 1st gear 2nd gear 3rd gear 4th gear RDckw&tsgang Final drive Final drive ratio 368 2941 I,44 1,oo 5,14 Drive pinion without hypoid displacement 15 : 33 i = 2,200 3,87 2,25 I,4 1,oo 5,59 14 : 33 i = 2,357 (A 28.02/05/08) 13 : 33 i = 2,538 (A 28.03/06/09/ 11/14/16'18) A 28.02/03/05/06/08/09/l 1 = 2200...2600rpm (Stall speed) A 28.01 = 2200...2600rpm Capacity, rear axle final drive Oil grade up to MY `86 = approx. 2.7 I from MY `87 to `90 = approx. 3.0 I MY `91 = 2.3 I* as of MY `92 = 1.9 I Multigrade transmission oil 75 W 90 to MIL L 2105 B or API classtication GL5 Total capacity = approx. 8.01 (`87 models onward, approx. 9.31). Capacity for fluid change with converter = approx. 6.01 (`87 models onward, approx. 7.31) ATF Dexron II D Capacity, auto. unl with converter * refer to Technical Information No. l/91 of 08.3.91 0 Technlcal Data Printed in Germany - XXXI. 1993 30 - 0103 928 General 30 TIGHTENING TORQUE FOR AUTOMATIC TRANSMISSION Location Description Threads Material Torque Nm (ftlb) 20 (14) Primary pump to front cover Plug (converter) Front cover to transmission Support flange to transmission Bolt M8 8.8 Bolt MlOxl 10.9 14 (10) Bolt case Bolt case Plug M8 8.8 13 19) M6 10.9 11 (8) Plug (brake band B 1 mount) Catch plate on range selector shaft Leaf spring to transmission M 27 x 1.5 - 70 (51) Bolt M6 8.8 8 (6) Bolt case 1 Bolt M6 8.8 8 (6) Starter interlock and backup light switch to transmission case Range selector lever to shaft Secondary pump to transmission case Governor on shaft axial hold M6 8.8 8 (6) 1 Bolt M6 8.8 8 (6) Bolt M6 8.8 8 (6) Nut M6 8 6 (4.3) Printed in Germany VI I I, 1984 Tightening Torques 30 0105 30 TIGHTENING General 928 TORQUE FOR AUTOMATIC TRANSMISSION Location Description Threads Material Torque Nm (ftlt 4 (3) d Lower cover with reinforcement Lower cover assy. to transmission case Bolt plate Bolt M5 5.8 M6 8.8 8 (6) Plug (test connection for modulating, governor and operating pressure) Vacuum Kickdown unit bracket solenoid valve Plug M8xl - 13 (9) Bokt Solenoid Bolt M6 M14x1.5 M4 8.8 8.8 8 (61 20 (14) 3.3 (2.3) End plate on valve body housing End plate on drive housing Drive housing to valve body housing Valve body housing to transmission ATF filter to lower cover Bolt M4 8.8 3.3 (2.3) Bolt M5 4.8 0.15 (0.1 I) 8 (6) Bolt M6 8.8 Bolt M5 8.8 4 (3) 0 30 - 0106 Tightening Torques Printed in Germany 928 General Data 30 a Tightening Location torques (automatic transmission) Thread Tightening Torque Nm (ftlb) Threaded plug (ATF pan) case MlOxl ME 22 (12) 8 (5.9) ATF pan to transmission Front converter casing to transmission case Carrier plate to converter Rear transmission cas to transmission case Bearing assembly to rear transmission case Final drive to transmission case Collar nut (drive pinion) M8 M8 23 (17) 46 (34) M 10 42 (31) ME 33 (24) M 10 M 26x 1.5 M 24 M6 46 (34) 380* (280) 78 (58) 6 (4.4) ATF filler tube to ATF pan ATF reservoir to ATF pan * As of MY `92 (transmission type A28.18) = 450 Nm (332 ftlb), 0 Tightening Printed torques (automatic transmission) - XXXI, 1993 30-0107 in Germany 928 Torque Converter 32 a TOOLS No. Description Special Tool Remarks 1 2 3 4 Transmission Grip plate Mandrel Depth gauge holder 9216 9301 9310 Standard tool a Printed in Germany - VIII, 1984 Removing and Installing Torque Converter 32 101 32 REMOVING Torque Converter 928 AND INSTALLING TORQUE CONVERTER I- i .-.-. -.-.-.- .-.-.-. -`-`-`-`-`/I-. I i y.<' .c'i 0-I @ -9 1 ! :/j / I 4123 a 32-102 Removing and Installing Torque Converter Printed in Germany 928 Clutch, Automatic Torque Converter 32 NC Description !tY. T Note Removing When: Installing I i Mounting bolt 6 8 Tightening 46 Nm (34 Tightening 23 Nm (17 torque: ftlb) torque: ftlb) Panhead bolt Washer 8 4 a 5 Front casing converter 1 Torque converter 1 Lift with 9301 out carefully Special Tool Renew if badly worn or if particles are found in ATF Lubricate drive flange and bearing pin with MoS multi-purpose gre i se. Place transmission upright and insert carefully using Special Tool 9301. Note installation depth. l I5 lutomatic transmission 1 - Printed in Germany - XVI,1987 Removing and Installing Torque Converter 32 - 103 ...