WM Porsche 928 Factory Manual - Vol 3

Workshop 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 Technical Data Paae 0.1
RepairGroups Group
Maintenance, Self-diagnosis 03
Engine Engine, Crankcase 10
Engine, Crankshaft, Pistons 13
Engine, Cylinder Head and Valve Drive 15
Engine, Lubrication 17
Engine, Cooling 19
Fuel Supply 20
Air Flow Controlled Fuel injection 24
Exhaust System/Emission Contrds 26
Starter, Power Supply, Cruise Control 27
Ignition System 28
Transmission Clutch, Controls 30
Torque Converter 32
Manual Transmission, Controls, Case 34
Manual Transmission, Gears, Shafts 35
Automatic Transmission, Controls, Case 37
Automatic Transmission, Gears, Valve Body 38
Differential, Transaxle System 39
Chassis Front Wheel Suspension 40

Rear Wheel Suspension, Axle Shaft 42
Wheels, Tires, Alignment 44
Antiblock System 45
Brakes, Mechanical 46
Brakes, Hydraulics 47
Steering 48
Body-Front Section 50
Body-Center Section 51
Body-Rear Section 53
Lids 55
Doors 57
Hardtop 61
Bumpers 63
Glasses, Window Control 64
Exterior Equipment 66
Interior Equipment 68
Seats 72
Seat Covers 74
Heating, Heater 80
Ventilation, Ventilation 85
Air Condition Air Conditioner 87
Electrics Instruments, Fuel Gauge, Alarm System 90
Radio 91
Windshield Wipers and Washer 92
Exterior Lights, Lamps, Switches 94
Interior Lights 96
Wiring 97
Printed in Germany - XX, 1997

928 Table of contents Volume III
Page
General Data
Technical data 30-0101
Tightening torques 30-0105
Torque Converter
Removing and installing torque convener 32-101
Removing and installing selector lever cover frame 37-101
Removing and installing selector lever cable 37-103
Adjusting selector lever cable 37-105
Removing and installing starter locking and backup light switch 37-107
Adjusting starter locking and backup light switch 37-109
Checking adjustment of selector lever cable and starter locking / backup light switch 37-l 11
Bowden cable for control pressure, removing and installing (service solution) 37-113
Bowden cable for control pressure, adjusting 37-115
Removing and installing transmission 37-l 17
Adjusting transmission suspension 37-123
Disassembling and assembling front convener housing 37-125
Disassembling and assembling front converter housing (‘87 models onward) 37-l 30
Removing and installing rear transmission case 37-131
Removing and installing rear transmission 37.135
Disassembling and assembling transmission 37-143
Transmission I Gears, Valve Body

Checking transmission operation .................... 38-101
Checking operation ........................... 38-l 10
Checking operation (87 models onward) ................ 38-11 Oa
Troubleshooting. ............................ 38-111
Removing and installing shift valve casing ............... 38-123
Disassembling and assembling shift valve housing .......... 38-l 25
Disassembling and assembling shift valve casing (‘87 models onward) 38-130a
Removing and installing lower cover .................. 38-131
Disassembling and assembling lower cover .............. 38-133
Replacing ATF and filter ........................ 38-137
Flushing ATF cooler and lines ..................... 38-141
Removing and installing governor ................... 38-143
Checking governor ........................... 38-145
Removing and installing vacuum modulator .............. 38-147
Removing and installing primary pump. ................ 38-149
-
Table of contents 1
Prlnwd in Germany- XXXV,1999
Volume III Table of contents 929
Disassembling and assembling secondaty pump ............... 38-l 55

Disassembling and assembling gear assembly ................ 38-l 57
Disassembling and assembling one-way clutch ................ 38-163
Disassembling and assembling clutch K 1 .................. 36-l 69
Disassembling and assembling clutch K 2 .................. 38-177
Differential I Transaxle system

Removing and installing final drive ...................... 39-l 01
Disassembling and assembling final drive .................. 39-107
Disassembling and assembling differential .................. 39-113
Disassembling and assembling bearing assembly .............. 39-l 19
Disassembling and assembling bearing assembly / Determining thickness of
shims for bearing assembly .......................... 39-123
Adjusting drive pinion and ring gear. ..................... 39-125
Disassembling and assembling central tube ................. 39-137
Checking central tube ............................. 39-139
PSD-Diagnosis I Troubleshooting ....................... D39-201
l
2 Table of contents
Printed In Genany - XXXV. 1999
928 General Data
30
4 - SPEED AUTOMATIC TRANSMISSION (UP TO '86 MODELS)
a
1 - Front converter casing 2 - Automatic transmission

a 3 - Final drive
Transmission Type installed in
A 28.01 928 S, USA series / '83 and '84 models for Japan
A 28.02 928 S, Special option for Europe / rest of the

world, '84 models
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)
A 28.04 928 S, USA series / '85 models for Japan
A 28.05 928 S, Special option Europe / '85 models

rest of 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)
A 28.07 928 S, USA series / '86 models for Japan
A 28.08 928 S, Special option Europe / '86 models

rest of 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)
A 28.11 928 S, Australia series, special option (M 299)

for FGR, Switzerland, Austria, Sweden
('86 models)
0 Printed in Germany-XX,1988 Technical Data 30 - 0101

30 General Data 920
0
Technical Data
4-speed automatic transmlsslon (‘87 models onward)
1 - Front converter casing 2 - Automatic transmission

3 - Final drive
Type Key-number Equipment Installed In model a
A28.12 - 928 S 4 USNJap. 87188
A28.14 - 928 S 4 R.d.W. 87188
A28.16 - 928 S 4 worldwide 89/90/91
A28.18 - 928 GTS worldwide 92/93
30 - 0102 Technical Data

Printed in Germany - XXXI, 1993
928 General Data 30
a
Technical Data
Tmsmlsslon DeslgnatTon
A 28 02 12 1 6 E 05065
T -r
[ - @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 722316 02.~ A28.01 7222702501 72231602...= A28.07

722 270 14 01 722 318 02...= A 28.02/03 7222702601 72231602.~ A28.11
7222701701 72231602...= A28.04 722 270 21 01 722 326 02...= A 28.12/14
722 270 18 01 722 318 02...= A 28.0.5/06 7222703201 72236003...= A28.16
722 270 21 01 722 318 02...= A 28.08/09 7222703401 72236003...= A28.18
Technlcal Data 30 - 0102a

30 General Data 928
Technical Data
Transmlssion numbers (12 dlglts)
A2814
T Index for varlants Model year Serlal

wlthln the assembly number number
J = 1988 e.g. 00903
0 = no differential K = 1989
1 = normal differential L = 1990
2 = ZF limited slip differential M = 1991
3 = proportional slip differential
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 a

Printed in Germany - XXXI. 1993
928 30
General data A28.0 1/04/07/l 2 R8.02/03/05/06/08/09/11/14/16/18
Fully automatic 4-speed sun-an&planet transmis m
Ratios A 28/t 6
1st gear 368 3,87

2nd gear 2941 2,25
3rd gear I,44 I,4
4th gear 1,oo 1,oo
RDckw&tsgang 5,14 5,59
Final drive Drive pinion without hypoid displacement
Final drive ratio 15 : 33 i = 2,200 14 : 33 i = 2,357 (A 28.02/05/08)

13 : 33 i = 2,538 (A 28.03/06/09/
11/14/16’18)
(Stall speed) A 28.01 = A 28.02/03/05/06/08/09/l 1 =

2200...2600rpm 2200...2600rpm
Capacity, rear up to MY ‘86 = approx. 2.7 I

axle final drive from MY ‘87 to ‘90 = approx. 3.0 I
MY ‘91 = 2.3 I*
as of MY ‘92 = 1.9 I
Oil grade Multigrade transmission oil 75 W 90 to MIL L 2105 B or
API classtication GL5
Capacity, auto. Total capacity = approx. 8.01 (‘87 models onward,

unl with approx. 9.31). Capacity for fluid change with converter
converter = approx. 6.01 (‘87 models onward, approx. 7.31) ATF Dexron II D
* refer to Technical Information No. l/91 of 08.3.91
0 Technlcal Data 30 - 0103

928 General 30
TIGHTENING TORQUE FOR AUTOMATIC TRANSMISSION
Location Description Threads Material Torque

Nm (ftlb)
Primary pump Bolt M8 8.8 20 (14)

to front cover
Plug Bolt MlOxl 10.9 14 (10)

(converter)
Front cover Bolt M8 8.8 13 19)

to transmission case
Support flange Bolt M6 10.9 11 (8)

Plug Plug M 27 x 1.5 - 70 (51)

(brake band B 1
mount)
Catch plate on range Bolt M6 8.8 8 (6)

selector shaft
Leaf spring Bolt M6 8.8 8 (6)

Starter interlock 1 Bolt M6 8.8 8 (6)

and backup light switch
Range selector lever 1 Bolt M6 8.8 8 (6)

to shaft
Secondary pump Bolt M6 8.8 8 (6)

Governor axial hold Nut M6 8 6 (4.3)

on shaft
Printed in Germany VI I I, 1984 Tightening Torques 30 0105

30 General 928
TIGHTENING TORQUE FOR AUTOMATIC TRANSMISSION
Location Description Threads Material Torque

Nm (ftlt d
Lower cover Bolt M5 5.8 4 (3)

with reinforcement plate
Lower cover assy. Bolt M6 8.8 8 (6)

Plug (test connection Plug M8xl - 13 (9)

for modulating, governor
and operating pressure)
Vacuum unit bracket Bokt M6 8.8 8 (61
Kickdown solenoid valve Solenoid M14x1.5 - 20 (14)
End plate on valve body Bolt M4 8.8 3.3 (2.3)

housing
End plate on drive Bolt M4 8.8 3.3 (2.3)

housing
Drive housing to valve Bolt M5 4.8 0.15

body housing (0.1 I)
Valve body housing Bolt M6 8.8 8 (6)

to transmission
ATF filter to lower cover Bolt M5 8.8 4 (3)
0
30 - 0106 Tightening Torques Printed in Germany
928 General Data 30
a
Tightening torques (automatic transmission)
Location Thread Tightening Torque Nm (ftlb)
Threaded plug (ATF pan) MlOxl 22 (12)
ATF pan to transmission case ME 8 (5.9)
Front converter casing to

transmission case M8 23 (17)
Carrier plate to converter M8 46 (34)
Rear transmission cas to

transmission case M 10 42 (31)
Bearing assembly to
rear transmission case ME 33 (24)
Final drive to transmission

case M 10 46 (34)
Collar nut (drive pinion) M 26x 1.5 380* (280)
ATF filler tube to ATF pan M 24 78 (58)
ATF reservoir to ATF pan M6 6 (4.4)
* As of MY ‘92 (transmission type A28.18) = 450 Nm (332 ftlb),
0 Tightening torques (automatic transmission) 30-0107

928 Torque Converter 32
a
TOOLS
No. Description Special Tool Remarks
1 Transmission holder 9216
2 Grip plate 9301
3 Mandrel 9310
4 Depth gauge - Standard tool
a
Printed in Germany - VIII, 1984 Removing and Installing Torque Converter 32 101
32 Torque Converter 928
REMOVING AND INSTALLING TORQUE CONVERTER
I-
i .-.-. -.-.-.- .-.-.-. -‘-‘-‘-‘-‘-

I
/I-. i
/
! I
y.<-
’ :/- j
.c’i
0-I
@-9 1
4123
a
32-102 Removing and Installing Torque Converter Printed in Germany
928 Clutch, Automatic Torque Converter
32
NC Description !tY.
T Removing
Note When:
Installing
I Mounting bolt 6 Tightening torque:

46 Nm (34 ftlb)
i Panhead bolt 8 Tightening torque:

23 Nm (17 ftlb)
Washer 8
4 Front converter 1
casing
a
5 Torque 1 Lift out carefully Renew if badly worn
converter with Special Tool or if particles are
9301 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.
lutomatic 1
l I5 transmission
-
Printed in Germany - XVI,1987 Removing and Installing 32 - 103

Torque Converter
928
a
/
r
NOTES ON REMOVING AND INSTALLING
I'
Removinq -yp? pf./

./,/‘” ,./ ;gzp,$
,J :
l.Remove transmission.
w
2.Using Special Tool 9216, attach
transmission to assembly support.
6.Attach Soecial Tool 9301 to

torque converter and carefully
lift out converter.
3.Place transmission upright and

working through the openings in ~~
the converter casing, remove
converter mounting bolts.
!
4.Remove mounting bolts for
converter casing and remove
casing. Installinq
Note:
5.Measure installation depth of
converter and make a note for If the ATF smells burnt or if the
reassembly. fluid contains particles of pad
material, torque converter and ATF
Up to '86 models = approx. 16 mm cooler must be rinsed.
'87 models onward = approx. 28 mm If particles of metal are found in
the ATF pan, the torque converter
must be replaced. Rinsing will not
remove all metal particles and
damage to the transmission may
result.
32 - 104 Removing and Installing Printed in Germany

Torque Converter
32
l.Rinse torque converter with

Special Tool 9310. To rinse, fill
converter with approx. 11 of
kerosine, insert the rinsing pin
and use a hand drill to turn the
pin at low speed. Then drain
kerosine off through drain plug.
Repeat rinsing 2 - 4 times until
the kerosine drained from the
converter is clean.
2.Attach Special Tool 9301 to

torque converter.
3.Coat drive flange and bearing

pin of converter with MoS2
multi-purpose grease.
4.Place transmission upright and

carefully insert converter,
turning unit in both directions
to engage the teeth.
5.Check installation depth of

converter.
Up to '86 models = approx. 16 mm

'87 models onward = approx. 28 mm

Torque Converter
928 Automatic Transmission/Controls, Case 37
REMOVING AND INSTALLING SELECTOR LEVER COVER FRAME
Removing
1. Remove selector lever grip and take off

rubber boot.
2. Move selector lever to position “2” and

push rear locking bar forward against stop
with a suitable tool (e. g. scribe).
6. Move selector lever to position “N” and

remove frame inclined toward rear.
Installing
1. Move selector lever to position “3”.
2. Push gate in frame forward all the way,

3. Move selector lever to position “R”,
disconnect gate and push forward as far as
possible. 3. Install cover frame in correct position and
move selector lever to position “P”.
4. Push front locking bar forward against stop 4. Push cover frame forward and move right
with a suitable tool (e. g. scribe). side to correct installed position (this is
done by lifting left rear corner slightly
and pushing down on right side).
5. Move selector lever to position “P” and

press out cover frame carefully with a
suitable screwdriver applied at the left rear 5. Push down on left rear corner until frame
corner. fits in center console correctly.
Printed in Germane - VIII, 1984 Removing and Installing Selector Lever 37-101
Cover Frame
a
6. Position selector lever between “R” and 9. Attach gate in selector lever, install
“P”, disconnect gate on selector lever and rubber boot in correct position and
push forward. install selector lever grip.
7. Push front locking bar toward rear until it IO. Move selector lever in and out of all
engages. positions and make sure that cover frame
fits properly.
8. Move selector lever to position “3” and

push rear locking bar toward rear until it
engages.
A - Locked
6 - Unlocked
37 - 102 Removing and Installing Selector Lever Cover Frame Printed in Germany
REMOVING AND INSTALLING SELECTOR LEVER CABLE
Removing 7. Disconnect selector lever cable on trans.

mission lever and detach cable sleeve on
brackets.
1. Unscrew ground strap of battery on body.
23
--- -:+@*> : ---,
2. Remove selector lever grip and take off i F,/’
rubber boot. 7c-
3. Remove cover frame (see page 37 101).
4. Pull bulb holder carrier out of retaining

clips.
5. Mark location of selector lever base for

reinstallation and remove mounting screws. 8. Take off ball head, hexagon nut and
mounting parts.
9. Attach tailing wire on cable and pull out

selector lever base with cable by pulling
forward at an angle.
6. Loosen intermediate muffler shield and

push aside as far as possible.
10. Remove cable circlip on selector lever

and detach cable sleeve on selector lever
base.
a
Printed inGermany VIII, 1984 Removing and Installing Selector 37 103
Lever Cable
Note:
If light opening of gate and letter “N” are

not exactly opposite each other in cover
frame, remove cover frame again and reposi-
tion selector lever base in slots.
6. Mount selector lever cable on transmission

as specified.
Installing 7. Adjust selector lever cable (see page

37 - 105).
1. Attach cable sleeve on selector lever base,

tightening the hexagon nut carefully.
2. Push cable on to selector lever pin and

install circlip.
3. Attach tailing wire, pulled forward during

removal, on cable and pull cable toward
rear, whereby one person should guide in
the selector lever base and a second person
must pull wire and cable.
4. Install selector lever base in correct

position (watching mark) and tighten
mounting screws with 15 Nm/ll ftlb.
5. Install cover frame and selector lever grip.

Place selector lever at “N”.
37 - 104 Removing and Installing Selector Lever Cable Printed in Germany

ADJUSTING SELECTOR LEVER CABLE
1. Move selector lever to position “N”. Note:
Bolt for range selector lever must be

2. Place range selector lever on transmission tightened for adjustments.
in “N”.
3. Adjust ball end on cable that attachment is

possible without tension.
l
Printed in Germany - VI II, 1984 Adjusting Selector Lever Cable 37 - 105
REMOVING AND INSTALLING STARTER LOCKING AND BACKUP

LIGHT SWITCH
Removing
1. Disconnect selector lever cable. 4. Pry off plug carefully with two screw
drivers applied on cable outlet and bar.
- in
‘/ - i3
-,fy!y;@-@+-q 2 ? .-”
.-w-y_..YQ;)(: .. -a -‘,&
? --’
+ of j,%gg$ -’
I q&.‘. .:‘y$g,(
2. Remove bolt for range selector lever and
pull off lever.
5. Remove switch mounting screws and take
off switch.
3. Unlock plug by turning white plastic ring

(arrow) upwards in direction of arrow.
IWJ
--- -- Installing
1. Install switch with both mounting screws,

but do not tighten.
Printed in Germany - VI I I, 1984 Removing and Installing Starter Locking 37.107

and Backup Light Switch
2. Install range selector lever that lug on

switch engages. Move range selector lever
to position “N”.
3. Install and tighten range selector lever

screw with 10 Nm (7 ftlb).
4. Adjust switch and connect plug (see page

37 - 109).
5. Attach selector lever cable on selector range

lever.
37.108 Removing and Installing Starter Locking and

a
Printed in Germany
Backup Light Switch
ADJUSTING STARTER LOCKING AND BACKUP LIGHT SWITCH
I. Insert locating pin made of 4 mm dia.

welding wire for 4 mm dia. drill) through
lug into locating bore in switch housing.
2. Tighten switch mounting screws with

10 Nm (7 ftlb) and pull out locating pin.
3. Press on plug and turn white plastic ring

down.
Printed inGermany VIII, 1984 Adjusting Starter Locking and Backup 37 - 109
Light Switch
CHECKING ADJUSTMENT OF SELECTOR LEVER CABLE AND

STARTER LOCKING/BACKUP LIGHTSWITCH
Move selector lever to position “N”. Run 6. Starting engine should only be possible
in “p” or ,TN”,
engine at fast idle speed.
Pull up parking brake lever and press down
on brake pedal for following tests.
7. Backup lights must be on in position “R”.
1. Move selector lever to position “R”. Engine

speed must drop as gear engages.
2. Move selector lever to position “P”. Engine

speed should increase as reverse gear
disengages.
3. Repeat test in point I.
4. Move selector lever to position “N”. Engine

speed should increase as reverse gear
disengages.
5. Move selector lever to position “D”. Engine

speed should drop as gear engages.
Printed in Germanv VIII, 1984 Checking Adjustment of Selector Lever 37 111

Cable and Starter Locking/Backup Light Switch
928 Automatic Transmission/Controls, Case
37
a
NOTES ON REMOVING AND INSTALLING
Removing
l.Remove top and bottom halves of air

filter(l6-valve engines only)
2.Disconnect control cable at engine.
.. . ;.d
.A,.
.;
tr /#-., CA”
I
32-valve engines ('87 models onward)
3.Sever bowden cable behind threaded

connector.
16-valve engines
4.Disengage control cable from trans-

mission by pressing locking
2B~~fi~ tab of guide as arrowed (arrow A)
i) 1. and turning guide anti-clockwise
! (arrow B).
l 1 ,;.?.y;-_ /F; .._1,*;\, !

[‘:.__.
t’ ; i ‘T‘Y.,,..:s,
I .e
h.b, I’ ” yi-‘13‘/.LI,,,j;,;,,;
4
T.;,- .-a“.--~1
F
32-valve engines (up to '86 models)
Printed in Germany - XVI,1987 Bowden Cable for Control Pressure, 37 - 113

Removing and Installing
(Service Solution)
Automatic Transmission/Controls, Case 928
37
5.Carefully lift out guide. 2.Install clamp correctly and

attach spherical head with hex
nut.
6.Detach control cable from actuat- A = Clamp

ing rod and pull out toward rear. 3.Attach Bowden cable to transmission
4.Adjust cable for control pressure

(see page 37 - 115).
Installing:
l.Carefully feed control cable

through sleeve from rear.
37 - 114 Bowden Cable for Control Pressure, Printed in Germany

Removing and Installing (Service Solution)
Automatic Transmission/Controls, Case
928
37
CONTROL PRESSURE CABLE, ADJUSTING
Note:
Correct adjustment of the Bowden

cable for control pressure is vitally
important for faultless operation
of the transmission.
l.Set idle speed.
2.Take up play in throttle cable.
3.Adjust spherical head of control

cable until cable can be installed
without strain.
32-valve engines (up to '86 models)
m’6 .I - .%
”, -t
r ’
.? .!
” h!
.+d: 1 . I
-1
16-valve engines
32-valve engines ('87 models onward)
Printed in Germany - XVI, 1987 Bowden Cable for Control 37 - 115

Pressure, Adjusting
a TOOLS
Universal transmission jack - Standard, e. g. from Hahn,

Metallbau GmbH
7012 Fellbach
Holding chain 9164
a
Printed in Germany VIII, 1984 Removing and Installing Transmission 37.117
REMOVING AND INSTALLING TRANSMISSION
Removing 5. Disconnect control cable on throttle

housing.
1. Unscrew battery ground strap on body.
2. Disconnect multiple pin plugs in spare

wheel well and pull out wires from below.
6. Disconnect oxygen sensor wire on central

fuse/relay panel and pull out from below
(USA cars).
7. Remove engine air guide.
3. Remove upper and lower air cleaner

housings.
8. Remove complete exhaust assembly with
shields.
9. Remove starter and suspend in suitable

position.
10. Drain ATF and remove reservoir.
11. Disconnect drive shafts on transmission

end and suspend on wire in horizontal
4. Remove upper air guide section. oosition.
a
37 - 118 Removing and Installing Transmission Printed in Germany
12. Remove rear axle cross member/trans 16. Disconnect selector lever cable on trans-
mission suspension mounting bolts. mission lever and unscrew cable sleeve
on holder and case.
13. Support transmission on stabilizer with

Special Tool 9164 (if necessary, lift trans-
mission on transmission support
slightly).
17. Remove feed and return lines for ATF

cooler. Plug open bores in case.
:
A .-- I
-,=,.I
9
[ i --- I,, *;
14. Mark position of toe eccentric and \ .,
rear axle cross member for reinstallation
. ~ .+,.&p
and remove entire rear axle.
~4+“’
1’: :-:;:y --_2; l? ,;~--
‘.ky.,e.~ ~-
15. Remove clamo bolt. ,. ‘2
fyqy-y.,-..!,.,,, ,g; : f ~, I __ ;
’ .;‘-~s;/~~~,, $ k&
3i,. P i.,‘“+.,, :,
--“up -*h “‘:
‘3)
.x;
-2 ff‘l
Printed in Germany VI I I, 1984 Removing and Installing Transmission 37 119

18. Pull off vacuum hose on modulating Disconnect control cable on operating
pressure box. rod.
19. Disconnect control pressure cable on

transmission. This is done by pushing
locking bar of guide in direction of arrow
(arrow A) and turning guide counter-
clockwise (arrow 6).
20. Place universal transmission jack under-

neath transmission and tighten rubber
strap.
21. Remove front and rear reinforcement

plates.
Pull out guide from above carefully.
a
37 - 120 Removing and Installing Transmission Printed in Germany
22. Lift transmission slightly and disconnect I. Place central tube in installed position
holding chain. with a suitably thick block of wood and
coat splines on central shaft with Optimoly
HT.
23. Lower transmission only far enough that
central tube/transmission mounting bolts
and control cable mounting bolt can be
removed.
i$- -4
\
{- ~.‘ 0 ‘; CT:: 9”
1.,. ‘\.. Y*.: +I ’
1 it -jx=.
’ ::.t I!-..
‘~--z;
___ (,. <.I?
2 I ‘a . z
a lib ,+ -.
,:i- ‘.- ‘., !.-T,
\
’
..,,
? ,;;a _~1 =-;. .,. ‘1 2. Lift transmission with universal trans-
mission jack and push on to central shaft.
24. Move central tube to installed position,

mount rear brace with two bolts and place
a suitably thick block of wood between
central tube and brace. n,
25. Pull back transmission and lower carefully.
Installing
-.
Note: ,q P;
R
Installation is in reverse order of removal ‘I
procedures, but also conform with following
points.
a Printed in Germany - VIII, 1984 Removing and Installing Transmission 37-121

3. Install and slightly tighten accessible bolts 9. Lower universal transmission jack.
on central tube flange.
10. Install rear axle and tighten all bolts

4. Lift transmission, remove block of wood and except for two transmission mount
take out brace again. bolts.
5. Lower transmission only far enough that 11. Lift transmission and disconnect Special
remaining bolts can be screwed in central Tool 9164.
tube flange (tightening torque: 120 Nm/
a7 ftlb).
12. Adjust transmission suspension (see

page 37 - 123).
6. Mount guide tube for control cable on
converter housing (tightening torque:
8 Nm16 ftlb).
13. Mount transmission on cross member
(tightening torque: 85 Nm/61 ftlb).
7. Push wire harness upwards through

opening in spare wheel well.
14. Check adjustment of selector lever and
control pressure cables, correcting if
necessary.
8. Lift transmission and hold in installed
position with Special Tool 9164.
a
37-122 Removing and Installing Transmission Printed in Germanv
a ADJUSTING TRANSMISSION SUSPENSION
The transmission mounts have to be adjusted Note:

to avoid tension in the transmission
suspension and to also guarantee good After tightening the mounting bolts there
insulation. must be at least 1 mm clearance between
the transmission case and stop on side of
transmission mount.
1 Install transmission and rear axle. Tighten

transmission mount/transmission case
mounting bolts with 85 Nm/61 ftlb.
a 2 Screw in cross member/transmission mount

bolts several turns.
3. Lift transmission in middle of case far

enough that there is a gap between both
transmission mounts and the cross member.
Measure this gap on both sides and take up
difference with shims.
4. Place shims of pertinent thickness between

transmission mounts and cross member,
lower transmission and tighten transmission
mounts/cross member bolts with 85 Nml
61 ftlb.
Printed in Germany VIII, 1984 Adjusting Transmission Suspension 37-123

a TOOLS
H
,-\ Lq--
..~.
/./ , - ,‘\
a \f
-.4
,a’. -‘*n,
a
Description Special Tool Remarks
Support rail - Standard

(e. g. Kukko, Size 1)
a Printed inGermany - VIII, 1984 Disassembling and Assembling Front 37-125

Converter Housing
928
a
DISASSEMBLING AND ASSEMBLING FRONT CONVERTER HOUSING
( .
(1
\
a
‘i ’i
\,?
i/ \
I 4’3
? “,
\
a
2 45 6 6
a
Disassembling and Assembling Front Converter Housing Printed in Germany
37-126
No. Description my. Note When: Special

Removing Installing Instructions
1 Circlip 1
2 Drive flange 1 Press out Press into case

with grooved ball
bearing (no. 4)
3 Spacer 1
4 Grooved ball 1 Press off with Heat to approx.

bearing support rail, 120 “C/250 “F
e. g. Kukko. and push on to
size 1 drive flange
5 Circlip 1
6 Circlip 1
7 Grooved ball 1 Press out with Heat case to

bearing suitable piece approx.
of pipe 120 “C/250 “F
and press in
with suitable
piece of pipe,
supporting with
drive flange
Printed in Germany VIII, 1984 Disassembling and Assembling Front 37-127

Converter Housing
DISASSEMBLING ~ANDASSEMBLlNG FRONT CXJfWEf?TEWfGUSING *
Disassembling Assembling
1. Remove circlip and press out drive flange. 1. Install both circlips in converter housing.
x_ I
77 ~~~-
F- __- ‘1 2. Heat grooved ball bearing to about
120 “C/250 “F and press bearing on drive
flange against shoulder with a suitable
piece of pipe applied on bearing inner
race.
3. Heat converter housing to about 120 “C/

250 OF and press in drive flange with
grooved ball bearing against circlip.
3’.
.^
; 1 r ’ ‘-$
:
.- L- -
i.-
2. Press grooved ball bearing off of drive flange

with a support rail (e.g. Kukko, size 1).
i
/- +-..
I
‘I / ._&:
_. b.z )-.
\
‘I !!!1 11
i:i
‘. . -,/ ,
I ‘1 pj,: 7: 31 .-
i. SLl!
0
iA- v ll
-x- -17 :T;

i-.-7
I 6; ,i
,’’ II iI
37-128 Disassembling and Assembling Front Converter Printed in Germany

Housing
37
4.Insert spacer sleeve and using a

suitable piece of pipe, press
front deep-groove ball bearing
over inner race until bearing
contacts circlip.
c- ‘r-“T -_-’
-~
l -71 _~ 1%
-1 -
m
~~ p-7 T
,.- .--- -- yj s i.. - ,:.;
,I--?! -
Note:
Place a suitable pressure piece

beneath the drive-flange bearing to
keep it from moving out as the
front bearing is pressed in.
Printed in Germany - XVI.1987 Disassembling and Assembling 37 - 129

Front Converter Casing
DISASSEMBLING AND ASSEMBLING FRONT CONVERTER CASING ('87 MODELS ONWARD)
37 - 130 Disassembling and Assembling XVI,1987 - Printed in Germany

('87 Models Onward)
37
a
-
Note when:
No Designation Qty Removing Installing
-
1 Circlip
2 Drive flange Press out Press in, after insert-

ing deep-groove ball
bearing (No. 5)
3 Deep-groove Pull off with puller Heat casing to approx.

ball bearing (e.g. Kukko, size 1) 120°C and press in as
far as possible with
a suitable piece of
pipe.
4 Spacer sleeve
5 Deep-groove Heat casing to approx.

ball bearing 12O'C and press in with
a suitable piece of pipe
6 Case
-
Printed in Germany - XVI,1987 Disassembling and Assembling 37 - 130 a

('87 Models Onward)
37
a
NOTES FOR ASSEMBLY AND DISASSEMBLY
Disassembling
1. Remove circlip and press out 2.Using puller (e.g. Kukko, size 1)
drive flange. pull deep-groove ball bearing off
drive flange.
11 a
r’ll ‘1
,;II i i
rz-i i &.,
-71 r -~
--/
2;‘
i i
,! !I+! :
( . ...&f&‘- & i
== !
-, ,- ,-- f-k-7
”
Assembling
l.Heat converter casing to approx.

120°C and install both deep-groove
ball bearings with spacer sleeve.
37 - 130b Disassembling and Assembling XVI,1987 - Printed in Germany

('87 Models Onward)
37
2.Press drive flange in as far as it

will go.
Note:
To prevent the deep-groove ball

bearing (No.51 movino out as the
flange is pressed, position a
suitable piece of pipe against the
bearing outer race as a support.
Printed in Germany - XVI,1987 Disassembling and Assembling 37 - 130 c

('87 Models Onwards)
a
TOOLS

I
1 Pressure pad 9180/l
2 Mandrel P 254
a
Printed in Germany - VI I I, 1984 Removing and Installing Rear 37 131
Transmission Case
37 Automatic Transmission/ContruIs, Case 928
REMOVING AND INSTALLING REAR TRANSMISSION CASE
I1
+\
2 I- ., I
;‘,3;9 _1’ ‘{j I(('i L I a
, I& s 5 ,- , ~_
,,;- ;p. 7T ji ~1, , 1
/- -
[I I I
da cii..k I/ i1 . ,r
i'I.\/
kiJIi'
9 6 5
37-132 Removing and Installing Rear Transmission Case Printed in Germanv

928 Automatic Transmission/Controls. Case 37
1 Bolt
M 10x55
-I
Qty.
Removing
Note When:
Installing
Torque:
42 Nm/30 ftlb
Special
Instructions
4
Bolt
M 10x40
Washer
Rear transmission
Torque:
42 Nm/30 ftlb
I
case
5 Race Insert after

installing case
l 6 Gasket 1 Replace
7 Seal 1 Drive out with Replace, drive

suitable screw- in to correct
driver position with
Special Tool
9180/l and coat
sealing lip with
ATF
8 Sea I 1 Drive out with Replace, drive

suitable screw- in to correct
driver position with
Special Tool
9180/l and coat
sealing lip with
ATF
9 Automatic 1
transmission
Printed in Germany VIII, 1984 Removing and Installing Rear 37-133

Transmission Case
a
REMOVING AND INSTALLING REAR TRANSMISSION CASE
Removing
---..-+;;R fimkkive-si=&+e
(see page 39 101).
2. Remove case mounting bolts.
a
Note:
Hold seal on special tool with a small amount

of grease and drive in seal that sealing lip
faces automatic transmission.
2. Drive in outer seal to correct position

with Special Tool 9180/l.
A = Five M IO x 55 bolts
B = Four M 10 x 40 bolts a
Installing
I. Drive in inner seal to correct position with

Special Tool 9180/I. Note:
Seal must be installed that its sealing lip

faces final drive.
a
37 134 Removing and Installing Rear Transmission Case Printed in Germany
TOOLS
r
m 1
2
Holder
Grip
9216
9301
3 Mandrel 9310
5 Centering pins 9321
6 Puller - Standard tool
7 Pressing in tool - Made locally

(steel pipe 45 x 5 x
40 mm with welded cover
and 11 mm dia. bore)
8 Pressure pad 9180/l
a PrintedinGermany - VIII, 1984 Removing and Installing Rear Transmission 37-135

REMOVING AND INSTALLING REAR TRANSMISSION
24
25 23
26
r
!---TA
(I J:1r;y22
\
,-.-.
?
-1
i .-._.- ‘.“ir,-.-.-. z.;.-.-.-.

19
18 i
11 12 13 14 15 16 li
37-136 Removing and installing Rear Transmission Printed in Germany

929 Automatic TransmisslonlControls, Case 37
No. Des&nation Qty. T Note:

Installation 1
1 Bolt 4 Torque:
46 Nm I33 ftlb
2 Washer 4
3 Holder 1
4 Collar nut 1 Torque:
46 Nm / 33 ftlb
5 Nut 1 Torque:
46 Nm / 33 ftlb
6 Washer 1
7 Bolt 1 Torque:
46 Nm / 33 ftlb
8 Washer
9 Final drive
IO O-ring Replace, coat with ATF
I1 Shim “S3” Determine thickness
I2 Collar nut Engage parking lock and Torque:
unscrew 380 Nm / 275 ftlb (as 01
mod. ‘92 = 450 Nm, 36
ftlb), and lock
I3 Bolt 6 Torque:
33 Nm I 24 ftlb
I4 Lock washer 6 Hollow side faces flangl
I5 Beartng assembly with 1 If necessary, pull out with If necessary, press in
drive pinion s suitable puller with locally made tool
Removing and Installing rear transmlsslon 37 - 137

Primed in Germany -XxX& 1993
37
-
No. Description 9 ty.
TRemoving
Note When:
Installing
16 Shim X Note number and Recalculate, if

thickness for necessary
reinstallation
17 O-ring 1 Replace, coat with

ATF
18 O-ring 1 Replace, coat with

ATF
19 Panhead bolt 2 Tightening torque:

6 Nm (4.4 ftlb)
20 Washer 2
21 ATF reservoir 1
22 Mounting bolt I5 Tightening torque:

46 Nm (34 ftlb)
23 Panhead bolt B Tightening torque:

23 Nm (17 ftlb)
24 Washer B
25 Converter casing 1
26 Torque converter' c 1 Lift out carefully Rinse with Special

with Special Tool Tool 9310. Install
9301 with Special Tool
9301.
A Mid-mounted
transmission 1
* Note installation depth:
Up to '86 models = approx. 16 mm

'87 models onward = approx. 28 mn
37 - 138 Removing and Installing XVI,1987 - Printed in Germany

Mid-mounted Transmission
REMOVING AND INSTALLING REAR TRANSMISSION
Removing 5. Position transmission upright and remove

converter mounting bolts through openings
in housing.
1. Remove transmission.
6. Remove converter housing mounting bolts

2. Mount transmission in assembly stand with and take off housing.
Special Tool 9216 and drain final drive oil.
7. Measure installed depth of converter

(about 16 mm) and note value for
reinstallation.
-‘y--JT
(‘& 14 p$.N
“. ’ i;+J;:
a 1 -- J ”
3. Engage parking lock and remove collar nut rfb~ I T ;
for drive pinion.
4. Remove bearing assembly mounting bolts

and pull off bearing assembly (use a 8. Mount Special Tool 9301 on torque con-
suitable puller, if necessary). verter and lift out converter carefullv.
. c,
b-1 M-7-T
m. I
? /CT%?,
‘, 6 i;r
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2‘,d’ \I\..:
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4
A = Bolt 10 x 30 with centering bore
PrintedinGermany - VIII, 1984 Removing and Installing Rear Transmission 37.139

Installing 2. Mount Special Tool 9301 on torque

converter.
Note:
The outer seal on the rear transmission 3. Coat drive flange and bearing journal of
between the transmission case and final converter with a multi-purpose grease
drive could be missing due to manufacturing containing MoS, additives.
conditions.
4. Position transmission upright and install

1. Drive in outer seal (if not already installed) converter carefully, while turning con-
to correct position with Special Tool verter back and forth until splines mesh.
9180/i.
Note: 5. Check installed depth of converter (about

16 mm).
Outer seal must be installed that sealing lip
and spring supporting the sealing lip face
final drive.
37 140 Removing and Installing Rear Transmission Printed in Germany

Note: 7. Install shims of determined thickness and
bearing assembly on output shaft.
If ATF smells burnt or contains metal
particles, torque converter and ATF cooler
must be flushed. er ’
If ATF sump contains metal particles, torque /q?+- ‘I
converter has to be replaced. Metal particles ,q ,‘,/ /,‘ r
could not be completely removed by flushing
, :‘: ,I ~ (11 I,
and would lead to transmission damage. -- Y
t
f--Y l \,;: I/
6. Determine thickness of shims for bearing L,, I i /4 A‘
A i r
assembly. Measure distance from tapered
-i
roller bearing surface to bearing flange ,, I 1
surface with a depth gauge (for example: -
34.55 mm). Since the distance specified by
design is only 34 f 0.05 mm, shims having
a thickness of 0.55 mm must be installed. Note:
Use Special Tools 9321 and a locally made

pressing in tool to make installation easier.
f--y7
e c;,
I?--
7‘)i -
f
/ - 1. i ;; r,I; k&T
ir, ;\ , ‘d;;1-:/” (
a g- I 41
/”-;.-;<. !?;t
Example:
34.55 mm Actual distance (measured)

34.00 mm Nominal distance (specified) 1 = Bolt from Special Tool 9148
0.55 mm Thickness of shims
2 = Washer
Printed in Germanv VIII, 1984 Removing and Installing Rear Transmission 37-141
48 AutomatlcTransmlssion/Controls, Case 920
a
8. Tighten flange nut for drive pinion to speci-
fied torque and lock by upsetting the flange
9. Adjust drive pinion and ring gear (see page

39 - 125).
10. Install transmission and check adjustment

of selector lever and control pressure ca-
bles.
a
37-142 Removlng and lnstalllng reartransmlsslon
TOOLS
: 2c
P-l@@\
f$-- ” 8 -1.
( 3~)
\
1 /
YI^. ---+--P7-
a
Designation Special Tool Remarks
Holder 9216 I
Assembly support 9316
Mandrel 9119
Measuring bridge 9313
Depth gage Commercia lly available
Circlip pliers Commercia llv available
(e.g. Hazet"1847 - 2)
Spacer sleeve 9312
Measuring device 9320
Centering pins 9321
a
Printed in Germany - XVI,1987 Disassembling and Assembling 37 - 143
Transmission
37
a
DISASSEMBLING AND ASSEMBLING TRANSMISSION
Disassembling
l.Attach transmission to assembly 5.Unscrew combination bolts and

support with Special Tool 9216. remove ATF pan with ATF reservoir.
Z.Remove final drive with bearing

assembly (see page 39 - 101).
3.Remove rear transmission case

(see page 37 - 131).
6.Unscrew cross-recess screws and

4.Remove front converter casing and remove filter.
converter (see page 32 - 101).
a
37 - 144 Disassembling and Assembling Transmission Printed in Germany

37
19.Unscrew hex bolt and remove Zl.Remove vacuum-control unit after

drive-range selector lever. unscrewing socket-head bolts.
ZO.Remove starter-interlock switch 22.Remove pressure unit B 1 and

after unscrewing mounting bolts. modulating pressure control valve.
~~ ----;-..
“’ .-a
/
r’ 7
6”--;
,,.\- \ c1
3 \> &$ !
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;-7’.*., -,I s$ , p$ 4 ,
,.. .’

Transmission
23.Remove kickdown solenoid 25.Remove plastic guide and roller.

valve and injector tube.
p y pLypc%z-<
1-4, ’ ‘,I i I
,?‘c.$ f ’ f
, p Lx-
, “g n
*..K
._ q” --’ ,c”
K - r-7
24.Remove parking lock with paw1

and expander spring. 26.Remove secondary pump by
unscrewing hex nut from axial
holder and removing socket-head
bolts.
P’ f- ‘;
P c
/ a-\ -
.~ ,L<-;:,*
1 ‘; ,‘I- y
$1 ,. /-
_ I
.-j

37
27.Remove O-ring and backer. 29.Unscrew socket-head bolt and

remove with oil tube.
The oil tube has been
discontinued as of model year
q ‘87.
i \ ;I t d.,$
-. ,’ -3
? .‘,i
. i
a
28.Remove circlip and sprung
linkage. The circlip has been
discontinued as of model year
'87. Linkage is staked to
detente plate.
30.Press in cover and remove

circlip.
a
Transmission
37
31.Withdraw cover. 35.A modified controller drive gear

was fitted as of approx.
December 1986. With this design,
32.Withdraw centrifugal-force remove spacer.
controller after swinging back
axial holder.
A = Spacer
8 = Circlip
33.Remove axial holder.
36.With a suitable pair of pliers

34.Remove helical gear with shims. (e.g Hazet 1847 - 2) disengage
Note thickness of shims for circlip from input shaft.
reinstallation.
a
37
37.Remove front cover by unscrewing 39.Pull clutch K 1 with brake band

combination bolts, screwing two B 1 from gearset.
bolts into the threaded holes
and using these to pull off cover.
40.Remove plates B 3.
1 41.As of transmission No. 379 225

--7 --’
.‘fl--“- - remove damping spring for plates
a. z.-
B 3.
38.Grasp gearset at input shaft

and carefully pull forward and
out.
A = Damping spring
42.Remove clutch K 2.
43.Remove pressure pin.
a
Transmission
928
a
44.Tilt brake band B 2 and remove. 47.Withdraw pressure unit B 2.
45.Unscrew socket-head bolt,

withdraw shaft and remove
detente plate.
TrV -y”’ L
/’,.I/ \ YA y A;
48.Unscrew hex bolts. Screw two

approx. 80 mm long bolts into
two opposite holes and release
flange from casing by tapping
the two bolts with a hammer.
46.Remove thrust washer 5lil

-q
’ ‘*;;T
a-
<, f 7 i
F==
-\-
,,.. -
.J
T+ F -/.-.
,?‘, a
2,:1 .-I(
49.Remove any remaining sealing

rings, measuring-connectFon
plugs etc. from case.
0
37
Assembling
Note:
When assembling, coat all bearings Z.Insert O-ring and sealing ring.
and friction surfaces with ATF. Screw in threaded plug with new
Soak new brake bands and coated sealing ring and tighten.
plates in ATF for approx. 1 hour Tightening torque 10 Nm (7 ftlb).
before installation.
l.Insert guide ring and with

Special Tool 9119, drive in
sealing ring right way round,
sealing lip (arrowed) facing
outward toward brake-band piston
a cover.
3.Place O-ring (arrowed) in groove.

Transmission
37
4.Grease grooves in support flange G.Position thrust washer right way

K 2. Insert teflon rings and round (positioning lug engages
press into grooves until joints support flange).
(arrowed) are closed.
T ~-y.q,\
-“,p” :2%- ‘\ ._
eF
,% !/ -.i z
s_ I :P “‘p
a\
..A\‘.
-. y
. ,.-‘..,’ -
(I., 7 ‘7*\ ‘J,&h& ‘5)
-,-z
m-j , >
e \ - -...-,-” “‘+9
f” ‘.p -3iq
p.,,. zJ,;i.F:”
\ -~~“’ = e.’ ic.
\,*\p
, . a
- t =G
7.Insert pressure unit B 2 with

projection (arrowed) upward.
S.Position support flange so that
holes are aligned. Tighten
mounting bolts. Tightening
torque: 11 Nm (8 ftlb).
a
37
8.Recheck to ensure that teflon ll.Push clutch K 2 onto gearset.

rings are correctly seated on
support flange.
9.Press brake band B 2 as close

together as possible at the
support lugs and insert right way
round in case.
lO.Place greased split radial

bearing on output shaft.
lZ.Carefully place gearset without

clutch K 1 in transmission case
while turning input shaft.
13.Set transmission upright with

input shaft at top.
---a--
Transmission
14.Check installation position of 16.Insert plates for plate brake

gearset. The gearset position is 8 3 right way round.
correct when the upper edge of
the connector element (arrowed)
is lower than the contact
surface of the outer plate LB 3.
v- --.-----IT. I ~---
l= Inner plate 2.1 mm thick

2= Outer plate 7.7 mm thick
3= Outer plate 2.3 or 2.8 mm
thick*
5= Shim 2.5-3.0-3.5 mm thick*
* as required to correct play
17.Measure play "L" of B 3 and

15.As of transmission No. 379225, correct.
install damping spring, Measure distance "d":
Place measuring bridge 9313 on
prepared face and measure with
depth gage to shim.
A - Damping spring

37
Measure distance "e": l- Inner plate 2.1 mm thick

Place measuring bridge 9313 on 2= Outer plate 7.7 mm thick
piston of plate brake and measure 3= Outer plate 2.3 or 2.8 mm
with depth gage to seal. thick*
5= Shim 2.5-3.0-3.5 mm thick*
* as required to correct play.
18.Place axial bearing in planet

carrier. Check that lubricating
pressure rings are correctly
seated (insert with grease).
A = seal
The difference between the two

distances is the play "L". Correct
play to specified value
1.5 . ..2.0 mm. Correct by inserting
outer plates and shims of
appropriate thicknesses.
19.Engage brake band 8 1 in

assembly lock (arrowed).
SF c-.1 - --‘,
.j
,,’ :
/,’ . ..- \

Transmission
928
20.Insert clutch K 1 while turning 25.Insert brake-band guide. The

until teeth engage. locating pins must engage the
holes in the case.
21.Insert brake band such that pin

is facing from assembly lock to
pressure unit B 1 (see Step 19).
22.00 not insert axial bearing and

shims until axial play of clutch
K 1 has been measured.
23.Push pressure pin into pressure

unit 8 1 (replace O-rings).
26.Check axial play "B" for clutch

K 1 and correct.
24.Insert pressure unit, screw in

threaded plug or transmission
protection switch in '87 models
onward and tighten. Tightening
torque 70 Nm (52 ftlb).
1 = Axial bearing
2 = Rotation washer
3 = Shim
B = Axial play
“?Z -.
.*. ?, .e
f% a;= ? .4.
.,I

37
Measure distance "a": Measure distance "b":
Place seal on front cover. Place Place measuring bridge 9113 on

Special Tool 9313 on flange and prepared face and, with depth gage,
with depth gage, measure to seal. measure to clutch K 1 (e.g. 123.6 mm)
(e.g. 119.0 mm).
The difference between the two

measurements is the axial play "B"
(without axial bearing, rotation
A = Spacer (discontinued as of washer or shim).
transmission No. 472 213)
B = Seal Example
"b" = 123.6 mm
ttaoo = _ 119.0 mm
4.6 mm
0.8 mm
-------- specified axial
play.
3.8 mm Play without axial
-------- beaking and
shims.
Note:
Correct play to 0.8 mm by

installing axial bearing, rotation
washer and the appropriate shims.

Transmission
Select axial bearing, rotation 28.With a blob of grease, attach

washer and shims such that the spacer to support and place
overall thickness is 3.8 mm. front cover with seal in
position. Tighten mounting
bolts. Tightening torque: 13 NM
(10 ftlb).
Insert these spacers as calculated
(thickness in example, 3.8 mm)
A - Centering pins 9321
29.Turn assembly support so that

output shaft is facing upward.
1 = Axial bearing
2 = Rotation washer
3 = Shim
a
27.Check that teflon rings in front
cover and on input shaft are
correctly seated.
a
37
a
3D.Insert circlip and position 32.Insert 0-ring.and install
spacer right way round. centrifugal-force controller
\
33.Swing axial holder over to
centrifugal-force controller so
that holder engages groove of
controller shaft.
Note:
The spacer has been in use since

approx. December, 1986.
31.Install helical gear and axial

holder.
I d’
’ A
‘,/ ‘J
I
a
Transmission
a
34.Insert cover and install 36.Place secondary pump in position
circlip. Then pull cover out so and tighten hex bolts.
that it makes contact with Tightening torque: 8 Nm
circlip around entire (5.9 ftlb).
circumference.
a
37.Recheck seating of axial holder
35.Install backer and insert and tighten new nut. Tightening
O-ring. torque: 6 Nm (4.4 ftlb).
e
37
38.Insert oil tube (arrowed) and 4O.Push roller onto sprung linkage,
tighten socket-head bolt. place plastic guide in position
Tightening torque: 8 Nm and push into positioning holes.
(5.9 ftlb).
The oil tube is discontinued as
of '87 models.
~.
~, \:
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J ; .L 1 ,gr
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- b,! 1. -- -r\ / LL‘-
39.Insert detente plate with shaft,

screw in socket-head bolt and 41.Place correct number of shims on
tighten. Tightening torque: 8 Nm helical gear.
(5.9 ftlb). Push sprung linkage
onto detente plate and install
circlip (arrowed).
The circlip is discontinued as
of '87 models. Linkage is staked
to detente plate.
+q..r _.
.+-’
0

Transmission
42.Install parking lock pawl, Use a depth gage to measure from

expander spring and parking lock rotation ring to seal (e.g.
gear. 15.3 mm).
43.Measure axial play "C" of output

shaft (clutch K 2) and correct.
A= Special Tool 9312

B= Rotation ring
c = Seal
bearing assembly:
Use a depth gage to measure from

7 = Taper roller bearing - inner bearing surface of taper roller
race bearing to bearing face of bearing
9 = Shim for bearing assembly assembly (e.g 34.55 mm). However,
10 = Shim for axial play "C" because the specified distance may
11 = Rotation ring not exceed 34 + 0.05 mm, 0.55 mm
C = Axial play must be made up in shims.
Measure distance "b":
Push Special Tool 9312 onto output

shaft and tighten collar nut.
Tightening torque 380 Nm
(280 ftlb). To do so, engage
parking lock pawl.
Place seal in position.

37
Use a depth gage to measure from

case bearing face to inner race of
cylindrical roller bearing (e.g
15.9 ml).
Example:
34.55mm As-is (measured on Distance "b" minus distance "a"

bearing assembly) equals distance "C".
- 34.00 mm Specified (design
distance)
-_______-__ Example:
0.55 mm Thickness of shims
Distance "a" 15.9 mm
Distance "b" - 15.3 mm
===:======
Install bearing assembly with shims Distance "C" 0.6 m
as calculated in case and tighten ==========
all mounting bolts. Tightening
torque: 33 Nm (24 ftlb).
Correct axial play "C" to 0.4 +
0.1 mm by inserting or removing
shims beneath parking lock gear.
,-K-
$,.““-+yt / Note:
,-’ .I /
,.F, 1, Remove bearing assembly from case
2h’-o-L < s, and do not reinstall finally until
F case is fully assembled (see page
37 - 131).
tr”* -b:,

Transmission
47.Install vacuum-control unit with

holder and tighten socket-head
bolts. Tightening torque: 8 Nm
(5.9 ftlb). Place starter
interlock switch in position and
slightly tighten mounting bolts
(do not tighten fully). Place
range selector lever in position
such that carrier is fixed in
lever. Insert hex bolt and
tighten.
Tightening torque: 8 Nm
(5.9 ftlb).
r
-7:y 1 y
. 2
i l
44.Insert injector
Discontinued
tube.
as of '87 models.
G’
,%A
) .:
45.Screw in kickdown solenoid valve

and tighten. Tightening torque:
20 Nm (15 ftlb).
46.Insert modulating pressure

control valve and pressure pin.
48 .Insert sealing ring with lip in

brake band piston B 1 such that
sealing lip is pointing in the
direction arrowed.
a
37
Note: 49.Bolt Special Tool 9316 to

transmission case and insert
Brake-band pistons with five brake band piston B 1 with
different pressure pins marked with compression springs and Special
grooves (arrowed) are available to Tool 9320. Screw spindle down
correct play at brake band 8 1. The while ensuring that piston
brake band piston with the shortest pressure pin enters brake band
pressure pin has no identification (do not damage sealing ring with
groove, the brake band piston with lip).
the longest pressure pin has four
identification grooves.
Brake band pistons with removable

pressure pins were installed as of
transmission No. 788 606. To
correct play, use shims available
in three thicknesses 0.5 mm, 1.0 mm
and 1.5 mm.
Note:
Play is set with either a flat or

pointed adjuster screw for Special
Tool 9320, depending on the design
of brake band piston.
Piston with rivetted pressure pin =

a hex screw with point
1 = Brake band piston B 1 Piston with removable pressure

2 = Pressure pin pin = flat hex screw M 10 x 1
3 = Sealing ring with lip
4 = Shims
5 = O-ring
d = Max. 6.5 mm

Transmission
Automatic Transmission/Controls, Case
37 928
50.Insert circlip, relieve Special

Tool 9316 and remove.
51.Measure and adjust play "L" of

brake band.
Note:
The thread of Special Tool 9320 has

a 1 mm lead, which means that one
full turn equals 1 mm travel.
Turn screw of Special Tool by

hand until resistance is felt.
a
37
Tighten screw further with torque 54.Install pressure pin with larger
wrench, counting turns and diameter toward brake band B 2.
tightening to 5 Nm (2.3 ftlb).
* -, .‘Vpq
p &q”:,,
r”
f.:;;.i,~ ;G>
“+$+++oQ$&~
7
9. ,+:: :’ 9 ,I
a ~~~&;;x&/.
.\ ’
55.Insert teflon ring with grease
in groove and insert pressure
Travel at brake band must be pin.
3 . ..4 mm, in other words, the 5 Nm
(2.3 ftlb) torque must be reached
after 3 . ..4 turns.
52.If travel is excessive, fit a

brake band piston with a longer
pressure pin; if travel is too
short, fit a brake band piston
with shorter pressure pin. As of
transmission No. 788 606, use
l appropriate
travel.
shims to correct
53.Place Special Tool 9316 in

position and bolt down. Remove
brake band piston B 1 and
install brake band piston cover
instead of Special Tool 9320.
a 37 - 169
Printed in Germany - XVI,1987 Disassembling and Assembling
Transmission
928
Note: 58.Measure play "L" at brake band

B 2 and adjust:
Pressure pins are available in 4 press brake band B 2 toward
lengths for correcting travel at brake band piston at support lug
brake band B 2. (as arrowed) so that brake band
piston contacts brake band
piston cover. Use a feeler gage
56.Insert brake band piston B 2, to measure distance "a" at brake
ensuring that pressure pin band.
engages brake band.
.
+-P
; ;” _ <z;_:
.:-:--i
95
(. /” /- \ _j /
/: -’ !\
J %f /-* J
1’
i/ I
Again, press brake band B 2 toward

pressure unit at support lug (as
57.Press in brake band piston cover arrowed) and measure distance "a"
B 2 and insert circlip. again.
a
37
The difference between the two 60.Insert brake band guide.

measurements is the play "L".
Adjust play "L" to 6...7 mm by
changing pressure pin in brake
band piston 82.
59.Insert one-way valve and filler.
61.Insert temperature throttle and

push into oil duct until throttle
is flush with casing. Insert oil
wiper.
a
Transmission
62.Install lower cover with back 64.Engage return spring.

plate, in so doing, insert oil
tube in casing bore.
-- -* ,,(
)‘, ‘,
a
65.Place leaf spring with holder in
position and tighten mounting
bolts slightly (do not tighten
63.Insert combination bolts and fully).
tighten nuts slightly (do not
tighten fully).
a
37
l
Note: 67.Insert combination bolts and
tighten to 8 Nm (5.9 ftlb).
Holder must be properly pinned in
place.
-8” ,qP--
i. I/-- .
Note length of bolts. The three
a arrowed bolts are only 50 mm long,
the remaining 12 bolts are 55 mm
long.
Begin by tightening the two bolts
A/B slightly to center the
shift valve casing.
66.Install shift valve casing,

range selector must engage
carrier on detente plate
(arrowed).
a 68.Tighten combination
back plate and leaf
bolts
spring
for
holder to 8 Nm (5.9 ftlb)
a
Transmission
928
a
69.Check clearance "a" between 71.Install oil pan with gasket,
locking piston and stop on screw down mounting bolts and
sprung linkage, adjust if tighten to 8 Nm (5.9 ftlb).
necessary. Use plastic clips to
adjust play to 0.4...1.0 mm with
selector in "N" position.
Plastic clips are available in
three thicknesses.
i
',
!:(' a
~~
';i
70.Place ATF filter in position,

insert cross-recess head screws
and tighten to 4 Nm (2.95 ftlb).
a
72.Set range selector to "N"

position, insert a holding pin
made of 4 mm welding wire (or 4
mm twist drill) through selector
into hole in shift valve casing
and tighten mounting bolts to
8 Nm (5.9 ftlb). Remove holding
pin.
Note:
Once the transmission has been

installed, check settings of cables
for selector lever and control
pressure and check modulating
pressure, reset if necessary.
0

Transmission
928 Automatic Transmission/Gears, Valve Body 38
a TOOLS
1
NO. Description Special Tool Remarks
1 Pressure tester v 90
2 Hoses 9170
3 Adapters 9300/l
Printed in Germany - VI I I, 1984 Checking Transmission Operation 38 - 101

CHECKING TRANSMISSION OPERATION
Prior to making repairs on an automatic trans, B-Transmission Fluid Level

mission, troubleshoot transmission as
instructed below and with help from the
following tests. The specified fluid level is extremely
important for proper operation of an
automatic transmission, so that following
A - General Checks test must be carried out with great care.
8 - Transmission Fluid Level
C - Stall Speed Check ATF Level
D - Test Drive
Also check appearance and odor of ATF.
E - Pressure Test Burnt friction linings cause a burnt odor.
Contaminated oil could cause failure in valve
body.
Caution!
All jobs, which require that engine runs, In this case transmission must be removed
should only be carried out with selector lever and repaired or replaced. ATF lines and
in “N” or “P” and parking brake applied. cooler must also be flushed.
Exceptions are tests, which require briefly a

different selector lever Dosition. ATF level check is carried out at engine idle
speed, parking brake applied and selector
lever at “N”. Car must be on level surface.
A- General Checks
Let engine run at idle speed 1 to 2 minutes
before checking fluid level, so that torque
Following jobs must be performed prior to converter will be full.
any testing of transmission, and if defects are
found, they must be eliminated before con-
tinuing with other work on transmission. ATF level can be checked on a cold or
warm transmisstion. However, the level will
be more accurate on a cold transmission
1. Check engine tuning (ignition timing, idle (20 to 3O”C/68 to 86°F ATF temperature)
and transition). than on a warm transmission (8O”C/176”F
ATF temperature). ATF temperature of
8O”C/176”F can only be estimated.
2. Check for external damage, e. g. leaks on
transmission (ATF) or final drive (hypoid
oil) and missing or loose mounting bolts.
38. 102 Checking Transmission Operation Printed in Germany

ATF level in transmission will change with fluid After correcting ATF level to specifications,
temperature. Max. and min. marks on transparent operate brake pedal, leave selector lever in each
tank are in reference to an ATF temperature of position (R-N-D-N-R) several seconds and then
80 ‘C. When ATF temperature is 20 to 30 “C, the return it to “N”, IO that working pistons of power
maximum ATF level will be below the minimum mark parts are filled with ATF. Recheck and, if
(see figure). The amount of ATF between min. and necessary, correct ATF level.
max. marks is 0.2 liters.
C -Stall Speed Test
This check provides information on operation of

engine, converter and transmission. It is applied,
when top speed cannot be reached or acceleration
is insufficient.
Note:
During this check all the engine power is converted

into heat in the converter, which is why this test
must not last longer than 5 seconds.
1 = max. at 80 ‘C ATF temperature
2 = min. at 80 ‘C ATF temperature
3 = max. at 20 to 30 “C ATF temperature Rear wheels must not be permitted to turn for this
check.
Also engine must be at operating temperature and

Add ATF to correct level. Cleanliness is essential! develop its full power.
Extra equipment, e. g. compressor for air con

If ATF level is too low, oil pump will draw in air, ditioner. must be turned off.
which can be heard. ATF will foam and cause
incorrect readings when checking ATF level. Stop
engine until ATF foam disappears (approx. 2 minutes) Check must not be made with car’s tachometer.
Add ATF and recheck ATF level.
1. Connect tachometer that it can be read from

driver’s seat.
Excessive ATF must be drained or drawn off, since
otherwise transmission components would splash
excessively and raise the temperature too much, until 2. Run engine at about 2,000 rpm approx
finally foamed oil is forced out through vent. This 2 minutes prior to testing.
condition could damage transmission on a longterm
basis.
3. Apply parking brake fully and depress brake
pedal with left foot.
Printed in Germany - ~11, 19 86 Checking Transmission Operation 38.103

(Transmission Type A 28.01)
38 Automatic Transmission Gears, Adjustment 928
4.Set selector lever to "Cl", fully D - Test Drive

depress gas pedal, transmission
must reach the specified stall
speed (see Technical Data, Take the vehicle for a test drive
page 30 - 0103). (only if transmission not obviously
damaged). During test driving, it is
important to pass through all the
automatic transmission ranges and make
Note: careful note of transmission response.
It is particularly important to note
If the stall speed drops some 400 speed and shift characteristics of the
to 700 rpm below the specified shifting points for upshift and down-
value, the torque converter shifts as well as the kickdown shift-
freewheel is slipping. ing points.
The transmission must shift gear

If the measured stall speed quickly and without loss of pulling
exceeds the specification by more force. A careful check should be
than 300 rpm, transmission slip made to see whether the engine
is the cause of trouble. accelerates suddenly as the gears
shift. Such acceleration indicates
that a brake or clutch is slipping.
If the engine does not reach
its top speed despite a correct
stall speed setting, the freewheel Experience in working with automatic
is blocking in both directions or transmissions is essential if the
is frozen. On the motorway, this unit's method of operation is to be
fault usually shows itself as a assessed and any faults identified.
leakage of ATF from the air bleeder. If this experience is not available,
it is advisable to compare the trans-
mission with a second unit of the
same rating and in verifiably sound
The drop in engine power with every condition.
1000 m of altitude above sea level
reduces the stall speed by After the test drive, check the trans-
approx. 125 rpm. mission for leaks.
The stall speed may also drop slightly

beneath the lower value if outside
temperatures are very high.
38 - 104 Operation, Checking XII, 1986 - Printed in Germany

a
928 Automatic Transmission/Gears, Control 38
l
Checking Operation
Shifting points in km/h

TransmissionType TransmissionType
A 28.01/04/07/12 A 28.02/05/08
km/h km/h km/h km/h
Selector lever position 1T u T1 u
Idle "D" 1-2-1 58...64 28...24 54...59 26u.22
Idle "D" 2-3-2 109...125 54...47 102...117 50...44
Idle "D" 3-4-3 190...211 131...115 177...197 122...107
Idle "2" 1-2 58...64 - env.63 -
Kick-down "D" 1-2-l 62u.68 45...39 58...63 42...36
Kick-down "D" 2-3-2 126...143 122...106 118...133 144...99
Kick-down "D" 3-4-3 207...216 203u.183 193...213 189...171
Kick-down '2" l-2 69w.75 - env.68 -
7 TransmissionType
A 28.03/O#6/C
19/;;/14
/TransmissionType
A 28116
Transmission Type
A 28.18
Gas pedal position km/h km/h km/h km/h km/h km/h
Selector lever positio Nn l-r u lT u l-l I”
50...55 24...21 41...50 30...23 41...50 3Ou.24
95...109 47...41 102...117 49...43 102...117 49...43
Idle "D" 3-4-3 165...183 114...100 169u.188 144...128 169...188 144...128
50...55 53...58 53...58 -

Kick-down "D" 1-2-l 54...59 39...34 59...61 48...43 57...58 47...42
Kick-down "D" 2-3-2 109...112 106...92 123...125 120...105 119...121 115...99
Kick-down "D" 3-4-3
Kick-down "2" l-2
I 180...188
60...65
Note: All speeds stated are approximations

176...159 192...195
59...61
186...167 180...189
56...75 -
180...162
Key to symbols: d Upshift

u Downshift
0 Checking Operatlon 38-105

38 Automatic Transm~ssion/Gears. Valve Body 928
E Pressure Test
This pressure test wll lndlcate any defects in the A pressure tester with up fo 25 bar pressure range
hydraulic control system. is required for measuring the operating pressure.
The 10 bar pressure wswr is applted for modulatmg
and governor pressure tests.
MEASURING NOMINAL PRESSURES

Pressure gauges are best connected. that they can
be read by driver durtng a test drove (if a dynamo
Automaftc fransm,ss~on IS f,tted wfh three measur,ng mewr is not avalablel.
~““nec,~o”s. so fha, the thrrp ,““I, imporfanf
pressures lmodulntl?g pressure. opernt~ng pressure.
governor pressure, can be measi;red Wlfh help Of a Tester IS set up in footwell in front of front
:ester mssenger’s seat. Pressure gauges are connected to
fhelr measurtng points by way of hoses. whtch are
gutded through wndow of r,ght door. Th,s requ,res
dlsconnectlng and pushing shield for rear muffler
astde.
Screw I” adapters for modulattng pressure and

go”ernor pressure co”“ect!ons.
i ,’
r. --z
i .,,. ‘A_ .--*-“” .q&&-A _I/:1
0 1
.. 2 -:.‘,‘, ‘$ .+. T’%* .* ~/y,#p! :.
1 I._,
1
i - Mndulating pre5rule
6 Governnr ~ressucc
A - Short adapter for modulattng pressure
E - Long adapter for governor pressure
38.106 Checking Transmission Operation Printed in Germanv

0
(Transmission Type A 28.01)
Connections for modulating and governor pressures
Connection for operating pressure
Note:
Do not let hoses hang through too much or rest on

the exhaust svstem.
Checking Transmission Operation 38 - 107

Printed in Germany VII, 1983
ITransmission Type A 28.01)
Modulating pressure, measuring
Note: Modulating pressure, adjusting
It is essential to measure the modu-

lating pressure and reset if neces- l.Remove rubber cover from vacuum-
sary, before testing any other control unit.
pressures. When the modulating
pressure is correctly set, the work-
ing pressure is produced of its own 2.Pull the retainer out slightly
accord. and adjust the setting screw
in the vacuum-control unit with
the retainer.
On the dynamometer or on the road,
accelerate to approx. 140 km/h with
the selector lever at "D" and check
the reading on the pressure gauge
(with vacuum line interrupted).
Note:
When working on K-Jetronic engines,

disconnect the vacuum line from the
intake manifold and plug socket with
a suitable bolt (e.g. plug for test
connection on transmission).
Note:
One full turn of the setting screw

changes the pressure by approx.
0.4 bar.
Clockwise:
Pressure is increased
Anti-clockwise:
Pressure is reduced
a
38 - 108 Checking Operation XVI,1987 - Printed in Germany
3. Lockplate must be pressed into nearest Measuring Governor

locking slot again after finishing adjust. Pressure
ment.
Since governor pressure is derived from

4. Recheck after finishing adjustment. operating pressure, operating pressure must
be checked simultaneously or previously.
Reference Information for Adjustments: Drive car on dynamometer or road and

compare governor pressure with values
One turn of adjusting screw changes pressure specified in table.
by 0.4 bar.
If no or deviating governor pressure is

measured, the governor must be
disassembled. cleaned and repaired.
Checking Operating
Pressure
Not adjustable; modulating pressure

automatically affects operating pressure. Control Pressure
Control pressure is part of modulating

pressure. It is regulated mechanically
depending on position of accelerator pedal.
If modulating pressure is adjusted correctly,

Checking Gove,rnor the control pressure will automatically be
Pressure correct.
Note:
Always disconnect vacuum line to check

governor pressure.
Governor pressure is part of operating

pressure and is brought to the necessary
value by the centrifugal governor.
a Printed in Germany -VIII, 1984 Checking Transmission Operation 38- 109

Automatic Transmission/Gears, Regulation
38 928
SPECIFIED PRESSURES IN BAR UP TO '86 MODELS
Test Transmission Transmission Testing Conditions

pressure We type
A 28.01/04/07 A 28.02/03/
05/06/08/09/11
Modulating 4.4 t 0.05 4.0 + 0.05 ATF temperature approx.

pressure* 8O"C, selector lever
at "D" speed
approx: 140 km/h
vacuum line discon-
nected from
modulating
pressure sensor
Working 16.9 ? 1 15.3 i- 1 ATF temperature approx.

pressure 8O"C, selector lever
at "D" , engine
idling, vacuum
line disconnected
from modulating
pressure sensor
Controller
pressure
approx.
approx.
approx.
0.2
1.1
2.0
approx.
approx.
approx.
0.2
1.1
2.0
at 20 km/h
at 50 km/h
at 100 km/h
T Selector
lever
at "D"
car moving
approx. 2.7 approx. 1.7 at 150 km/h in partial-
load range
vacuum line
discon-
netted
l
from
modulating
pressure
sensor
If local conditions do not permit a test at approx. 140 km/h, measurements

may also be taken at.approx. 50 km/h.
a
38 - 110 Checking Operation XVI,1987 - Printed in Germany
928 Automatic Transmlsslon. Gears. Shafts 38
Checking functioning
Nomlnal pressures In bar as from Model ‘87
Test pressure
T Gearbox type
A 28.12/14/16 A 28.18
Measuring conditions
Modulation pressure’ . 4.2 k 0.05 4.4 f 0.05 ATF temperature approx. 80X,
Selector lever in position D, driving
speed approx. 140 km/h,
Vacuum line disconnected at the
modulating pressure cell
Working pressure 16.0 * 1 15.8 f 1 ATF temperature approx. 80 ~ C,

selector lever in position D, engine
a speed 1400 rpm, hand brake
applied and servicebrake actuated,
Test no longer than
5 seconds. Vacuum line dis-
1
connected at the modulating
pressure cell
i
I
I
Controller pressure IA 28.14/16 A 28.1: A 28.18
approx. 0.2 0.17 0.45 at 20 km/h Selector level in position D
approx. 1.l 0.96 1.40 at 50 km/h Vehicle moving in partial-load range
approx. 2.0 1.74 2.15 at 100 km/h Vacuum line disconnected at the
approx. 2.7 2.35 3.10 at 150 km/h, modulating prssure cell
* Note
If the focal conditions do not permit testing at approx. 140 km/h, measurements are still possible
at approx. 50 kmh.
Funktion pr9fen (ab Mod. ‘67) 36-110a

l TROUBLESHOOTING AUTOMATIC TRANSMISSION
Note: If transmission oil is black and smells burnt or there is an unusual large
amount of metal particles in oil pan, either repair or replace transmission.
Condition:
Transmission slips in all selector lever positions.
Cause/Correction:
1. Check modulating pressure, adjusting if necessary.

If not adjustable, check movement of modulating
pressure control valve.
2. Check whether vacuum line from intake branch to

vacuum box is plugged. If yes, replace.
3. Check operating pressure. If too low or not available:
a) Disassemble and clean shift valve housing and

service valve. Replace shift valve housing if
necessary.
b) Remove and inspect primary pump, replacing if

necessary.
Condition:
2nd gear slips or transmission shifts from 1st to 3rd gear.
Cause/Correction:
1. Check movement of control valve B 1, replacing shift

valve housing if necessary.
2. Remove and install brake band B 1 piston and check

seal, replacing if necessary.
3. Replace brake band B 1 and pressure element for B I.
Printed inGermany VIII, 1984 Troubleshooting 38. 111

Condition:
Transmission slips when moving off in 1st and 2nd gear, or moving off not possible in
forward gear. Reverse gear is still good.
Cause/Correction:
1. Service shift valve B 2. replacing shift valve housing if necessary.
2. Replace brake band B 2 piston
3. Adjust brake band 8 2 by installing a longer thrust pin.

Replace brake band in case or excessive wear or broken brake
band.
Condition:
Transmission slips during 2nd/3rd shift, or slips at first and then grabs hard.
Cause/Correction:
1. Check modulating pressure, adjusting if necessary,
2. Check whether temperature orifice is installed (see removing

and installing lower cover on page 38 131).
3. Replace shift valve housing.
4. Replace inner plates of clutch K 1. Repair clutch depending

on findings.
Condition:
Transmission slips during 3rd/4th shift.
2. Replace shift valve housing.
3. Replace inner plates of clutch K 2. Repair clutch depending

on findings.
a
38 112 Troubleshooting Printed in Germany
Condition:
After installation, transmission has no power flow or fails after a brief time of operation,
Cause/Correction:
Torque converter not installed according to instructions.

Drive dogs do not engage accurately in drive gear of
primary pump.
Follow-up damage: Torque converter drive dogs and

primary pump will be destroyed.
Replace primary pump and, if necessary, torque converter.
a
Condition:
No power flow in all selector lever positions for a brief period immediately after starting
engine (especially when car had not been used for a while).
Cause/Correction:
Torque converter drains partially via leaky or defective

lubricating ring on drive shaft or via leaky lubricating
valve in shift valve housing.
1. Check lubricating ring on drive shaft, replacing if

necessary.
2. Check and clean lubricating valve in shift valve housing,
Condition:
No power flow in reverse gear.
Cause/Correction:
1. Check lined plates and seals on piston of brake band 3,

replacing if necessary.
2. Replace one-way clutch in gear set
a
Printed in Germany VIII, 1984 Troubleshooting 38 113
Condition:
Strong jolt when engaging selector lever in “D” and “R”.
Cause/Correction:
1. Adjust idle speed and CO level to specifications.
2. Check modulating pressure, correcting if necessary
3. Check whether spring is installed underneath valve

ball (5) in shift valve housing (see page 38 126).
4. Check vacuum line and connections for leaks.
5. Check whether pressure acceptance piston in shift

valve housing moves easily and is in correct installed
position, replacing shift valve housing if necessary.
Note: If there is a hard engagement jolt when quickly shifting back and forth
between “N” and “D” several times, there is no fault. The pressure pick-up
requires a running time of approx. 2 seconds. If this time is given, the
engagement jolt will also be correct.
Condition:
Strong jolts when changing gears.
Cause/Correction:
2. Check vacuum line and connections for leaks
a
38-114 Troubleshooting Printed in Germany
a
Condition:
Strong jolt in downshift from 4th to 3rd gear.
Cause/Correction:
1. Replace seal on release end of B 2
2. Replace brake band piston B 2
3. Pressure element of B 2 has turned; replace pressure

element.
a Condition:
Jolts when shifting in partial load range.
Cause/Correction:
1. Check adjustment of control pressure cable.
2. Check modulating pressure, adjusting if necessary
3. Check vacuum line and connections for leaks.
Condition:
Shaking during upshifts.

a
Cause/Correction:
Check whether screen restrictor with spring is installed

(see page 38 126).
Printed in Germany VI I I, 1984 Troubleshooting 38 115

No upshifts.
Cause/Correction:
1. Check governor pressure. If there is no governor

pressure reading, continue with point 2. If governor
pressure is correct, continue with point 3.
2. Clean and service centrifugal governor.
3. Disassemble and clean shift valve housing. replacing

if necessary.
Condition:
Upshifts only in upper speed range of gears.
1. Check and adjust control pressure cable
2. Check governor pressure and replace centrifugal

governor, if governor pressure is too low.
3. Service control pressure valve
Condition:
Upshifts only in lower speed range of gears.
Cause/Correction:
1. Check whether control pressure cable is disconnected

or torn, and then adjust accurately.
2. Check full throttle stop. Move accelerator pedal from

full throttle and check whether throttle is against
full throttle stop, adjusting if necessary.
3. Check governor pressure and replace centrifugal

governor. if governor pressure is too high.
38. 116 Troubleshooting Printed in Germany

928 Automatic Transmission - Gears, Regulation
38
Fault:
No kickdown from 3rd to 2nd

shifting points in partial load range too low
Cause/remedy
check gas and control pressure cable settings
Fault:
No kickdown downshifts
Cause/remedy:
l.Check fuse for power supply to solenoid

valve.
- Z.Remove solenoid valve. With valve removed, connect to power
supply and check operation. Fit replacement if necessary.
3.Check that control pressure cable is not disconnected, broken or

maladjusted.
4.Check that kickdown control slide moves freely in housing, in-

stall replacement housing if necessary.
Fault:
No brake shifts (4-3 and 3-2)
l.Adjust control pressure cable.
l Z.Check vacuum lines and connections for leaks.
3.Release brake shift plunger, if necessary separate shift slider

housing.
a
Printed in Germany - XII, 1986 Faults and Remedies 38 - 117
38 Automatic Transmission/Sears, Valve Body 928
Condition:
Automatic, unwanted downshifts outside of partial throttle downshift range,

without operation of kickdown switch.
Cause/Correction:
1. Remove kickdown solenoid valve.

Check O-ring on solenoid valve for damage
2. Check whether kickdown switch sticks in pressed

position, replacing if necessary.
3. Check whether solenoid valve sticks in open position,

replacing if necessary.
Condition:
Poor acceleration when moving off.
1. Check stall speed
2. If stall speed drops below specified value by approx

400 to 700 rpm. one-way clutch in converter
is slipping. Replace torque converter.
l
38. 118 Troubleshooting Printed in Germany
Condition:
Selector lever cannot be engaged in “R” and “P”.
Cause/Correction:
a) With engine running

b) With engine stopped
1. a) Clean and service centrifugal governor
2. b) Service blocking piston in lower cover.
Condition:
Engine cannot be started with selector lever in “P” and “N”.
Cause/Correction:
1. Adjust selector lever cable and starter interlock

switch.
2. Replace starter interlock switch.
Printed in Germanv VIII, 1984 Troubleshooting 38 119

-
Condition:
1st and reverse gears too loud.

-
Cause/Correction:
1. Replace front gear set depending on findings.
Note:
First and reverse gears are louder than the other
gears because of the ratio. A different car should
be used for comparison.
Condition:
3rd gear too loud.
Cause/Correction:
1. Replace rear planet gear set.
Condition:
Whining noise only when changing gears with full load.
Cause/Correction:
1. Replace oil filter.
Condition:
Whining noise, which increases in loudness as engine speed rises,
Cause/Correction:
1. Check primary pump, replacing if necessary.
a
-
Condition:
Invisible oil loss (leak cannot be seen on outside) in conjunction with smoke in exhaust.
Cause/Correction:
Diaphragm in vacuum box is defective. ATF drawn in

by engine via vacuum line.
1. Replace vacuum box.
Condition:
Oil lost between torque converter and primary pump

(oil escaping through vent grid).
Cause/Correction:
1. Install oil drain plug on torque converter with a

new seal as well as Hylomar on threads, and
tighten. If still leaking, continue with point 2.
2. Replace radial oil seal and O-ring of primary

pump, inspecting O-ring groove in primary pump
for porous spots. Replace primary pump,
if necessary.
Printed in Germany VIII, 1984 Troubleshooting 38. 121

Condition:
Rattling noise at engine speed of 1500 rpm in all selector lever positions, except “R”
Cause/Correction:
Plates of reverse gear brake swinging in transmission case.
1. Replace inner plates of reverse gear brake B 3;

adjust play to smallest value.
Condition:
Light grinding noise in selector lever positions “P” and “N”.
Cause/Correction:
This noise concerns a normal rolling noise from the

front gear set, which cannot be eliminated.
Condition:
Chattering noise when driving in reverse gear
Cause/Correction:
Play of plate brake B 2 excessive. Outer plate carrier

of K 1 scraping on piston of B 3,
1. Adjust play to specified value (1.5 to 2 mm).
a
YZ8 Automatic Transmission/Gears, Control
38
REMOVING AND INSTALLING SHIFT VALVE CASING
Removing
l.Remove drain plug and drain ATF. 3.Unscrew mounting bolts and remove
shift valve casing.
Installing
Z.Remove ATF pan by disconnecting l.Ensure that plastic poppet valve

breather holes for ATF reservoir and chip screen for shift valve
and removing mounting bolts. B 2 are'correctly seated.
A- Plastic valve
B- Chip screen (use in series
production as of Nov. '85,
transmission No. 729 001)

Shift Valve Casing
2.Place shift valve casing in 4.Install ATF pan with gasket and
position, range selector valve tighten mounting bolts.
must engage carrier. Tightening torque: 8 Nm
(5.9 ftlb).
3.Insert mounting bolts and 5.Screw in drain plug with new

tighten. Tightening torque: 8 Nm sealing ring and tighten.
(5.9 ftlb). Tightening torque 14 Nm (8 ftlb)
6.Top up ATF.
Note:
The full-throttle control pressure

can be changed by turning the
socket-head bolt (arrowed). Turning
the bolt clockwise makes the full
load or kick-down upshifts earlier.
Turning the bolt anticlockwise
makes the uoshifts later.
Note:
Center shift valve casing by first

tightening the two bolts A/B
slightly.
The three bolts marked with arrows

are 50 mm in length, the remainder
are 55 mm long.
7.Check setting of control-pressure

cable and readjust if necessary.
a
Shift Valve Casing
2.Place shift valve casing in 4.Install ATF pan with gasket and
position, range selector valve tighten mounting bolts.
must engage carrier. Tightening torque: 8 Nm
(5.9 ftlb).
3.Insert mounting bolts and 5.Screw in drain plug with new

tighten. Tightening torque: 8 Nm sealing ring and tighten.
(5.9 ftlb). Tightening torque 14 Nm (8 ftlb)
6.Top up ATF.
Note:
The full-throttle control pressure

can be changed by turning the a
socket-head bolt (arrowed). Turning
the bolt clockwise makes the full
load or kick-down upshifts earlier.
Turning the bolt anticlockwise
makes the upshifts later.
Note:
Center shift valve casing by first

tightening the two bolts A/B
slightly.
The three bolts marked with arrows

are 50 mm in length, the remainder
are 55 mm long.
7.Check setting of control-pressure

cable and readjust if necessary.

Shift Valve Casing
DISASSEMBLING AND ASSEMBLING SHIFT VALVE HOUSING
18 1 234 5 678 9
l
*i4.$
*I .cb , --* :-y; I;?‘& &
--&
I;
#-
: ,I .F$;: >.,’‘)$J
-. : i -i,, ,s_
,i’L i ?
?F ;*
L
*c-* c=l*A4 * \
hi ,-.- . c- \..
& *
r* %
‘*.
.r= 4
‘. 6
I_ ..’,i$ ‘w-
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,.
#-* L1
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16 Ii 15
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a
PrintedinGermany - VIII, 1984 Disassembling and Assembling Shift Valve 3a- 125
Housing
a
DISASSEMBLING AND ASSEMBLING SHIFTVALVE HOUSING
..-.--_ _,
a
38.126 Disassembling and Assembling Shift Valve Housing Printed in Germany
Vo. Description Qtv. Note When: Special

I- Valve ball ia Install conical

18 (5.5 mm dia.) spring with large
diameter end
facing down
underneath ball
no. 5
I9 Plastic valve 1 Install in

flight without correct position,
bore) do not mix up
with valve
without bore
a !O Throttle check 1
valve
21 Check valve 1 Install with spring
22 Lubricating 1 Install with spring

pressure operating
pin
23 Orifice 1 Install with spring
24 Valve 1
25 Operating pin 1 Unlosable
a
Printed inGermany VIII, 1984 Disassembling and Assembling 38.127
Shift Valve Housing
a
DISASSEMBLING AND ASSEMBLING SHIFT VALVE HOUSING
Disassembling
Note:
Absolute cleanliness is essential for any work

on the shift valve housing. If at all possible
work should be done on a plastic lined work-
bench (leather sheets would be especially
suitable). After disassembling all parts must
be washed and dried with compressed air. ,J a .TI~m.‘n,*:
m ~#j li1 c-
1. Remove plastic valve. a
3. Hold and turn shift valve housing and

pick-up housing around.
4. Lift off pick-up housing with transfer

plate carefully.
A = Plastic valve
8 = Check valve
C = Operating pin
D = Blocking valve K 1
2. Remove both mounting bolts (arrow). 5. Take out all valves and balls.
38 128 Disassembling and Assembling Shift Valve Housing Printed in Germany

Assembling 4. Place pick-up housing on shift valve
housing.
1. Place all balls and valves in shift valve

housing (see layout drawing). 5. Hold shift valve housing and pick-up
housing together and turn both around.
2. Install lubricating valve, modulating

pressure valve and vent valve K 1 in pick- 6. Screw in both bolts, but do not tighten.
up housing.
n
.1P.~’ --
,-.&s-t •~~.y~+~~~
T~gyg$yzz-f % :-: - -‘--c.r*
I” ,hi~~~(~~~L.--l
j&g%zg%<k
pTy.z d &' -..;G:;.;p;.qy
C,.” ‘) p$y’- ,_& ,.:.
." Ti; -?J.~ -a.-, +-- +,--
& %(, .I< ;g“ .‘I, -::‘;;q ; - ,= -7 _ ,-"6- ., "$y- -*
h .’ s r+ g,y I' ,, c ;; I-*
::> s ‘, .,I2,‘,f/
Ir, ‘1
n II. - 0. CT ,yd I” A,“$/., i .? ,. .I ,_*.
* .---~L ‘1- +y I _ _ n
0 0 I ,* I>
A = Lubricating valve (unlosable) Note:

B = Modulating pressure valve (onlosable)
Tighten bolts only enough that both housings
C = Vent valve (onlosable)
can still be moved to align them.
3. Place transfer plate on shift valve housing 7. Install plastic valve (green) in housing that
carefully and check whether valve ball bore is in correct position.
(arrow) is in correct installed position.
..-I.; “-.
_ ._ ._ -_- .:- --.
--
- .. -.. - -z - --- :
r)
~~~~~~~
. LL h
A = Plastic valve
Printed in Germany - VI I I, 1984 Disassembling and Assembling Shift Valve 38-129

Housing
928 Automatic Transmission/Gears, Control
38
a
DISASSEMBLING AND ASSEMBLING SHIFT VALVE CASING ('87 MODELS ONWARD)
a
Printed in Germany - XVI,1987 Disassembling and Assembling 38 - 130 a
Shift Valve Casing
('87 Models Onward)
928
DI'SASSEMBLING AND ASSEMBLING SHIFT VALVE CASING ('87 MODELS ONWARD)
19 26 27 20
.\I \ I I I ’
a>) ---*d.,r ;
“7;,,=<iQ&1’: qy,” ,j~==-=.q,
/
18 A. I, ./,>,A$
38 - 130 b Disassembling and Assembling Printed in Germany

Shift Valve Casing ('87 Models Onward)
38
Note When:
No. Designation NY. ?emoving Installing
l.., Valve ball 18 Insert taper spring with

18 (dia. 5.5 mm) large diameter downward
beneath ball No. 5.
19 Plastic valve Insert right way round,

(light, withou t do not mix up with valve
bore) with bore
Throttle check
l 2o valve
21 Check valve Install with spring
22 Shift pin, Install with spring

lubricating
pressure
23 Throttle Install with spring
24 Valve
25 Shift pin :aptive
’ 26 Valve
27 Throttle* Install with spring

(with spring)
* At the start of series production the throttle was installed in some cases
and was later discontinued without replacement.
a
Printed in Germany - XVI,1987 Disassembling and Assembling 38 - 130 c
Shift Valve Casing
('87 Models Onward)
928
NOTES FOR DISASSEMBLY AND ASSEMBLY
Disassembling
Note: 2.Remove both mounting screws

(arrowed).
It is essential to maintain
absolute cleanliness during all
work on the shift valve casing. If
possible, spread a plastic sheet on
the workbench beneath the parts
(moleskin cloths are particularly
suitable). After disassembly, wash
all parts and blow through with
compressed air.
l.Remove plastic valve and chip

screen.
rn~
.- - .y.mz,. - .I 3.Hold shift valve casing and
z----r E~,z$$4 and turn
sensor housing together
;~s;q~Lkz&q~~&~~
r”-j over.
rc-.-g=&J ,T,sl&g ~-ZI~;
r_p&L~3~~~:
4.Carefully lift off sensor housing
g-_+-& G HL?-cQ ” *, with back plate
-2 ..I .fP*- - I.-l,
, ‘I+?/3 -’_“ii T e;’
. ... n c
b B A
A - Plastic valve
B - Check valve
C - Shift pin
D - Lock valve K 1
E - Chip screen
5.Remove all valves and balls.
38 - 130 d Disassembling and Assembling Printed in Germany

38
Assembling 3.Carefully place back plate on

shift valve casing and check that
l.Place all valve balls and valves in valve ball (arrowed) is in its
shift valve casing (see exploded installation position.
drawing).
2.Install lubricating-pressure
valve, overpressure modulating
valve and bleed valve Kl in
sensor housing.
4.Place sensor housing on shift

valve casing.
5.Hold shift valve casing and

sensor housing together and turn
over.
A = Lubricating pressure valve
(captive)
6.Insert both screws (do not
B = Overpressure modulating valve tighten).
(captive)
C = Bleed valve (captive)
Printed in Germany - XVI,1987 Disassembling and Assembling 38 - 130 e

Shift Valve Casing
('87 Models Onward)
928
Note:
Tighten screws so that housing and

casing can still be moved against
each other.
7.Insert plastic valve (yellow)

in casing with bore and chip
screen right way round.
A = Plastic valve
B = Chip screen
38 - 130 f Disassembling and Assembling Printed in Germany

REMOVING AND INSTALLING LOWER COVER
Removing Installing
1. Remove shift valve housing. 1. Check for proper seating of temperature

orifice, plastic valve, filler and oil
deflector.
2. Remove ATF filter.
3. Remove holder and leaf spring.
0 w
;--
6
.
-ryw . .-* .m-. . ..---
ew
?y ‘7;
'Sq..,' <T
B ~’ - ;
4. Remove combination bolts and take off
cover with oil tube.
,H”“““~>
l
<” /
743 a
A = Temperature orifice
B = Plastic valve
C = Filler
D = Oil deflector
Printed in Germany - VI I I, 1984 Removing and Installing Lower Cover 38-131

2. Mount lower cover, guiding oil tube into

bore.
3. Install combination bolts, but do not

tighten (tighten bolts with 8 Nm/6 ftlb
only after installing the shift valve housing)
4. Mount leaf spring with holder and install

bolt but do not tighten (tighten bolt with
8 Nm/6 ftlb only after installing the shift
valve housing).
5. Install shift valve housing and tighten

combination bolts with 8 Nm/6 ftlb
(including bolts on lower cover).
6. Install ATF filter and tighten phillips

screws with 4 Nm/3 ftlb.
l
38 - 132 Removing and Installing Lower Cover Printed in Germany
a
DISASSEMBLING AND ASSEMBLING LOWER COVER
.A’
.‘---...
\
.
we’
*
r / ._
,’ 1 -,~_/
I
I
f’ r
- . .
* ,~
Printed in Germany VI I I, 1984 Disassembling and Assembling 38-133

Lower Cover
No. Description my. Note When: Special

1 Oil tube 1
2 Injector 1 Squeeze tabs Install in correct

together and position
remove
3 Bolt 4 Torque:
8 Nm/6 ftlb
4 Cover 1
5 Gasket 1 Replace,
if necessary
6 Transfer plate 1 a
7 Filter screen 2
8 Valve 1 Position correctly,

check for tight
fit
9 Holder 1 Position correctly
I IO Plug 1
I1 Spring 1
I2 Shift valve 1 Install with ATF

secondary pump
13 Circlip 1
1’
14 Sleeve 1
I’
15
16
Shaft
Spring
1
I’
17 Sleeve 1
I’
18
I9
Circlip
Blocking valve
1
1 Coat with ATF
I20 Housing 1
a
38-134 Disassembling and Assembling Lower Cover Printed in Germany
928 Automatic Transmission/Gears, Valve Body
38
a
DISASSEMBLING AND ASSEMBLING LOWER COVER
Note: Assembling
Absolute cleanliness is essential for any work

on shift valve housing and lower cover. 1. Install shift valve secondary pump with
Work should be performed with a plastic liner spring and plug, and secure with holder.
on the workbench whenever possible. Never
use cloths losing lint.
-%i=s~~,.~*~ -
’ ..’ d- _ --’ -k
_-” I*.‘::I “Ic.--<
,. -
.. -5’ -
.I -i ;:
1. Squeeze both tabs together and remove

injector.
2. Insert blocking valve with spring and

shaft, and install circlip.
2. Remove filter screens and valve.

r.
c‘
3. Take off circlip. Remove blocking valve
with spring and shaft.
Printed in Germany - VI I I, 1984 Disassembling and Assembling Lower Cover 38-135

3. Install valve and filter screens in correct 7. Insert injector in correct position until
position. both tabs (arrows) engage.
4. Place transfer plate and gasket on lower

cover.
5. Align gasket with transfer plate by inserting

two bolts.
6. Mount cover and tightan mounting bolts

with 8 Nm/6 ftlb.
38-136 Disassembling and Assembling Lower Cover Printed in Germany

38
a
TOOLS
-;c’h
I
I
,I!
/i
.P
- Filler - Commercially available,

e. g. Dresser-Wayne
Model 3009
Printed in Germany . VIII, 1984 Replacing ATF and Filter 38-137

38 Automatic Transmission - Gears, Regulation 928
AFT AND FILTER, CHANGING
Filling Capacities Turn crankshaft until the con-

verter drain plug is visible and
After drainage approx. 8.0 1 can be removed.
After oil change approx. 6.0 1
Types of oil:
ATF Dexron B - sperm-oil free
The ATF and the filer must be changed

every 40,000 kilometers.
Note
If a vehicle is subjected to particu-

larly severe wear and tear (e.g.
used for towing) the ATF should
be changed every 20,000 km (without
replacement filter) k'hen ATF ceases to drain from
the oil pan and torque conver-
ter, remove transmission oil
If the ATF is to be changed, the pan and install replacement ATF
vehicle must be standing on level filter.
ground, the transmission must be hot
and the engine switched off.
qpx!yy--lyTq a.v kAh-.-f

Unscrew drain plug from oil pan and
drain the ATF into a suitable contain-
er.
a
38 - 138 ATF and Filter, Changing XII, 1986 Printed in Germany
928 Automatic Transmission - Gears, Regulation
38
Install oil pan with gasket and
yF ~
torque retaining bolts with 8 Nm
(8.7 ftlb).
/
Screw in plugs with new seals
tighten with 14 Nm (10.2 ftlb).
and
/ ..r;
_-
Refilling with ATF
Before starting the engine, use

a filler to pump most of the
ATF (approx. 5 1) into the oil pan.
Keith the selector lever at "P"
a start the engine and allow to 86 models onward
idle. Observe the ATF level in the
reservoir and top up with the rest of Operate service brake and set the
the ATF without delay. selector lever to each position
for a few seconds. Recheck ATF
level.
N 0 t e
The level of ATF in the trans-

mission varies with the temperature
of the fluid. The marks (max. and
min.) on the resevoir are indexed
for an PTF temperature of 80" C.
However, at temperatures between
20 and 30" C, the maximum ATF level
is below the minimum mark (see fig.).
This fact is of importance, as the
ATF is usually changed at these
temperatures.
Up to 85 models
Printed in Germany - XII, 1986 ATF and Filter, Changing 38 - 139

38 Automatic Transmission - Gears, Regulation 928
Up to 85 models
86 models onward
1 = max. at 80°C ATF temperature

2 = min. at 80°C ATF temperature
3 = max. at ZO-30°C ATF temperature
XII, 1986 - Printed in Germany

l
38 - 140 ATF and Filter, Changing
a
FLUSHING ATF COOLER AND LINES
Note: 3. Attach extra hose from ATF charger (see

Workshop Equipment Group of Special
If ATF smells burnt and there are metal Tool Catalog) on return line and flush
particles, sludge or liner abrasion in oil pan, cooler as well as lines with the charger.
it is not sufficient to only replace the valve
body or transmission. The ATF cooler and
lines will also have to be flushed with ATF.
1. Disconnect return line on transmission case

and take off short hose on return line.
4. Catch ATF running out of feed line.
2. Disconnect feed line on transmission case

0
Printed in Germany VIII, 1984 Flushing ATF Cooler and Lines 38-141
REMOVING AND INSTALLING GOVERNOR
Removing
1. Loosen intermediate muffler shield and 4. Loosen nut for axial holder.
push aside as far as possible.
2. Unlock plug for starter locking and backup

light switch by turning up white plastic
ring in direction of arrow. Pry off plug
carefully with two screw-drivers applied on
both sides.
5. Turn axial holder counterclockwise with

a screwdriver inserted in slot (correspond-
ing with position “B” in sectional view).
3. Press in cover and remove snap ring with

cover.
1 = Cover
2 = Snap ring
Ip;+ 3 = Governor
\. ‘1 4 = Axial holder
5 = Axial holder nut
6 = Secondary pump
Printed in Germany VI I I, 1984 Removing and Installing Governor 38 - 143

6. Pull out governor.
Installing
1. Guide in governor.
Note:
Absolute cleanliness is necessary for installa-

tion of governor. If necessary, cover area of
governor installation with lint free cloths. Note:
Axial holder has been installed correctly

when slot is horizontal (position “A” in
2. Move centrifugal governor lightly in and section drawing).
out while turning axial holder clockwise
until governor engages firmly (position “A”
in section drawing).
4. Press in cover and insert snap ring.
5. Press out cover again until it rests on snap

ring.
4
6. Press on plug for starter locking and

backup light switch. Lock by turning
white plastic ring down.
‘.’
,---
.,-.A
iyc.8 T-‘-q-
1 = Cover
.b.Jpw :-j
2 = Snap ring
3 = Governor J$&< Q,’
4 = Axial holder
,“, ‘- r:y “$&L--i’
5 = Axial holder nut -* I
6 = Secondary pump ‘+
.. -m&-&z+
3. Tighten axial bearing nut to 8 Nm/6 ftlb. 7. Bolt shield.
a
38-144 Removing and Installing Governor Printed in Germany
a
Checking Governor
Move centrifugal weight “A” and at same time

check movement of governor valve in
openings (arrows).
Note:
It should be possible to move governor valve

easily. If necessary, wash governor and dry
thoroughly with compressed air.
Printed in Germany - VI I I, 1984 Checking Governor 38-145

a
REMOVING AND INSTALLING VACUUM MODULATOR
Removing
1. Loosen intermediate muffler shield and 2. Adjust modulating pressure (see page
push aside as far as possible. 38 - 108).
2. Pull off vacuum hose on vacuum modulator.
3. Remove socket head screws and remove

with holder.
. .--. ,.
4. Pull out vacuum modulator

a
Installing
1. Mount vacuum modulator with holder and

tighten socket head screws to 8 Nm/6 ftlb.
a
Printed in Germany - VIII, 1984 Removing and Installing Vacuum Modulator 38-147
Automatic Transmission/Gears, Valve Body 38
a
TOOLS
NO.
1
J Description
Guiding sleeve
Special Tool
9319
I
Remarks
2 Centering pins 9321
Printed in Germany VIII, 1984 Removing and Installing Primary Pump 38. 149
a
REMOVING AND INSTALLING PRIMARY PUMP
12 13 14 15 11 16
III-L 1
a?@&*!“:
-“i’ ’
L.-.-.-.-.-.-.-.-.-.-.-.-.
-!
A;-‘- , p/
I
r i
,p
.j a
I
6
a
38-150 Removing and Installing Primary Pump Printed in Germany
38
Note When:
No. Description QW. Removing Installing
-i Thrust washer 1
2 Teflon ring 2 Replace, install with

grease.
3 Circlip 1
4 Spring plate 1 Insert right way round
5 Compression 20
spring
6 Piston Insert right way round
Sealing ring Sealing lip must face

a 7 Nith lip toward cover
8 Sealing ring 1
with lip
9 iex bolt 1 Tightening torque:

20 Nm (15 ftlb)
10 Spring washer 6
I
il 'ump casing 1 1 ICheck bearing sleeve
for damage
12 sacker Install right way round
13 'ump gear
ldriving)
Pump gear Bevel faces toward

(driven gear) bearing sleeve
15 D-ring Replace, coat with ATF
16 Sealing ring Drive in with suitable

pressure piece
17 Zover
* As of transmission No. 472 213, the pin on the cover (No. 17) has been
extended. The thrust washer is no longer installed.

Primary Pump
NOTES FOR REMOVING AND INSTALLING
Removi nq
Note:
It is not necessary to disassemble

the transmission to remove or
install the primary pump.
l.Remove transmission.
Z.Remove front converter casing and

converter.
3.Unscrew mounting bolts for front 6.Unscrew mounting bolts and remove
transmission cover. pump; screw two bolts in threaded
holes and carefully drive out
primary pump with light taps of a
4.Screw two bolts in threaded holes nylon-headed hammer.
and pull bolts to withdraw cover.
Installing
l.Check bearing sleeve for grooves

or signs of damage. If damage is
discovered, the primary pump must
be replaced.
5.Press spring plate down and

remove circlip.

Primary Pump
2. Lubricate both pump gears with ATF and
install in pump body, whereby the large ,: h
gear must be installed that the chamfer
(arrow) faces bearing sleeve.
5. Apply Special Tool 9319 on front cover

and coat sliding surfaces with ATF.
6. Coat seals on piston with ATF and install

piston that journal (on piston) and bore
3. Screw Special Tools 9321 in pump body. in front cover are aligned.
Place transfer plate in correct position and
install pump in front cover. Bearing sleeve
must not be damaged by the stator shaft 7. Press in piston carefully and without
during this step. Tighten mounting bolts to canting, driving in with a suitable pin
20 Nm/14 ftlb. applied on outer seal (arrow) if necessary.
,‘I II
k.ik++~/>,:I
. %M-’
4. Install seals on piston that sealing lips face

down (direction of arrow).
Printed in Germany VIII, 1984 Removing and Installing Primary Pump 38-153
38 Automatic Transmission/Gears, Valve Bodv 928
8. Install return springs and diaphragm spring.
9. Slide circlip over Special Tool 9319, hold

circlip down and pull off special tool.
10. Push down on diaphragm spring with

circlip until circlip engages in its groove.
11. Install teflon rings with grease, making

sure gap of rings (arrow) remain together.
If necessary, take off rings again and
shape them carefully to a smaller
diameter.
38 154 Removing and Installing Primary Pump Printed in Germany

38
DISASSEMBLING AND ASSEMBLING SECONDARY PUMP
2 1 4 3
1.
3‘-,
5 I.
‘pc I.
.J
1) /.-’ /*- .- ./*- 01
/.-*
.I 6.
-
:-;
L c
a +
II
8 6 i
Printed inGermany VIII, 1984 Disassembling and Assembling 38-155

Secondary Pump
No. Description Qty. Note When: Special

1 O-ring 1 Replace if
necessary.
Coat with ATF
2 Transfer plate 1
3 Gear (driven) 1 Coat with ATF
4 Gear (driving) 1 Coat with ATF;

drive dog must
engage in groove
5 ’ Circlip 1
6 Cover 1 -
7 Spring 1
8 O-ring I 1 Replace, coat

with ATF
!
9 Piston / ,
10 Teflon ring Replace, install

: l in groove
with grease
!
11 Teflon ring 1 Replace. install
in groove
I
with ATF
12 Body / 1
l
38. 156 Disassembling and Assembling Secondary Pump Printed in Germany
a
TOOLS
Assembly stand 9314
a
Printed in Germany VI I I, 1984 Disassembling and Assembling 38.157
Gear Assembly
DISASSEMBLING AND ASSEMBLING GEAR ASSEMBLY

a
23 4
+$j
,is US!, 3
‘I -- ---Y c.
; L-
\ ,$rz
-&
2
--l 1
h
_.--
5.
-G
_
t- =I
*c/
i ); i
i
J
_r~.:d
.-.-.-.-.-,-.-.-.-.-.-.-.A i
r 10 9
i
q v -\*ld
i
r .-.
-.-. -.-.- .-.-.-._._._.
. 11 12 14 13
I r ~\ &
i ;$$i~ $lL~ .\, L-~,e.,u~$Z,
-+I,.-
1)
'j&j G,. 'IiT-; =1'? i
” );. ] *
$
i
r .-.-.-.-.-B ._.-._.-._,-. 1 l
!
! /I
I
-jwr;
15 16 5 17 18
38 158 Disassembling and Assembling Printed in Germany

Gear Assembly
do. Description Qty. Note When: Special

1 Clutch K 1 1 Lnstall only after

gear assembly is
in case
2 Axial bearing 1
3 Thrust washer 1
4 Shim X Note thickness Redetermine

for reinstalla- thickness if
tion necessary
5 Snap ring 1 Remove with a Check for correct

suitable screw- fit
driver
6 Front gear set 1
7 Axial bearing 1
a Drive shaft 1
9 ! Axial bearing 1
IO Lubricating ring 2 Replace, install

with grease
I1 Radial bearing 1
12 Axial bearing 1
I3 : Drive shaft
l i
14 Radial bearing 1 Install with

(split) grease
15 Axial bearing 1
16 Sun gear 1
inner plate carrier 1

with one-way clutch
I- -A-
Printed in Germany VI I I, 1984 Disassembling and Assembling 38 159

Gear Assembly
a
DISASSEMBLING AND ASSEMBLING GEAR ASSEMBLY
Disassembling
I, Clamp Special Tool 9314 in a vise on both 3. Take off parts separately.
surfaces with plate facing up and mount
gear assembly with drive shaft facing up.
4. Remove snap ring and take inner plate
carrier with one-way clutch out of
connecting carrier
Assembling
2. Remove snap ring.

Note:
Coat all bearing surfaces and sliding surfaces

with ATF when assembling.
1. Place one-way clutch with connecting

carrier on Special Tool 9314.
38-160 Disassembling and Assembling Gear Assembly Printed in Germany

2. Mount sun gear and install axial bearing.
CT-v-- ‘7 ”
;’
;*
( :, 5 L,~ n ‘I,YJ.a ??
,_),.
iI@, - ,,‘,*r.‘:
.--::,,.
,,,& *
:.
‘,
\
b +k+++~
A
‘\
3. Install output shaft. 6. Install front gear set and secure with snap
ring. Press snap ring into groove with a
screwdriver.
4. Install axial and radial bearings on output
shaft.
5. Install drive shaft and axial bearing 7. Lift gear assembly off of Special Tool 9314
and install again with drive shaft facing
Printed in Germany VIII, 1964 Disassembling and Assembling Gear Assembly 36 - 161
8. Install split radial bearing on output shaft 10. Take gear assembly off of Special Tool
with a small amount of grease. 9314 and install axial bearing on drive
shaft with a small amount of grease.
A’ 1 I ,-. I
I -.-.* ,.-.-- 3 _ ‘;~.I,
_ j:,,
r ;- ,;; “A, “_ ;y-,
I ,* i +-<;p.“)4 _., ~, .’
6, ” *, \j,,>T ‘it
9. Install clutch K 2.
(b
38-162 Disassembling and Assembling Gear Assembly Printed in Germany
a
TOOLS
-
a
1 Lockplate 9322 Sixteen (16)
t
2 Feeler blade gauge
I - Standard tool
Printed in Germany VIII, 1984 Disassembling and Assembling 38-163

One-wav Clutch
DISASSEMBLING AND ASSEMBLING ONE-WAY CLUTCH
-\ ,
--
I ii1.-* ---
-* A i
-.-•
.--
12
a
38-164 Disassembling and Assembling Printed in Germany
One-way Clutch
a

1 Snap ring 1 Check for

correct fit
2 Connecting carrier 1
3 Shim X Redetermine
thickness,
if necessary
4 Support 1 Position correctly
5 One-way clutch 1 Use Special

inner race Tool 9322
a
6 Shim 1
7 Roller cage
1 ’ :
8 Cyl. roller ! 16 I
9 Spring I 16 ,
! (
IO O-ring 1 Replace, install ~
~ 1 after checking
axial play
I1 One-way clutch 1 Check for wear

outer race
I2 Thrust washer 1 Tabsengage

in plate carrier
a
! 1I3 O-ring 1 Replace
I ’I4 Plate carrier 1
L I
a
One-way Clutch
0
DISASSEMBLING AND ASSEMBLING ONE-WAY CLUTCH
Disassembling
1. Remove snap ring and lift inner plate carrier I. Place thrust washer and O-ring on inner
K 2 with one-way clutch out of connecting plate carrier.
carrier.
2. Turn inner race of one-way clutch counter- 2. Install cylindrical rollers in roller cage.
clockwise and pull out.
.*fip-!.p>~&
Assembling zi- :I;-
*, . s ri,
: .A
/
Note: 1 p+ &‘,
*‘I j-p$,~,~p ,i
Check bearing surfaces and inner race of one-
way clutch for wear.
If bearing surface of cylindrical rollers on
inner race of one-way clutch shows strong
scoring or notching, replace the entire one-
way clutch.
Coat bearing surfaces and sliding surfaces
with ATF.
38-166 Disassembling and Assembling One-way Clutch Printed in Germany

3. Place outer race of one-way clutch on inner
plate carrier and install roller cage in
correct oosition.
6. Remove Special Tool 9322.
7. Install shim.
4. Push cylindrical rollers against springs and

apply Special Tool 9322 with bend facing
out.
Note:
Install O-ring only after checking axial play

of one-way clutch.
5. Install one-way clutch inner race while
turning in direction of arrow.
Printed in Germany - VI I I, 1984 Disassembling and Assembling One-way Clutch 38-167

8. Install support that pin engages in bore

(arrow) of one-way clutch outer race.
/’p4* “, (_
-.‘- .. b,
;:me.;:. :
ffq yy ,. I _ ‘1
‘*‘-4
Checking and Adjusting

One-wav Clutch Axial Play:
9. Place shims (if available) on outer race of 1. Check play between one-way clutch and
one-way clutch and install connecting connecting carrier with a feeler gauge.
carrier on one-wav clutch.
I
,
10. Install snap ring and press into groove 2. Adjust play to 0.05 0.2 mm with
with a screwdriver. shims.
3. Install O-ring,
38 168 Disassembling ans Assembling One-way Clutch Printed in Germany

a
TOOLS
2
,’ff+-+----+b .-.
!’1 _- ,
3 ;,“-
l ,,/’.- j \ .../z
1’
??+-
,j\ \

t
1 Assembly tool 9315
2 Assembly sleeve 9317
4 Feeler blade gauge - Standard tool
Printed in Germany VIII, 1984 Disassembling and Assembling 38 - 169

Clutch K 1
DISASSEMBLING AND ASSEMBLING CLUTCH K 1
L.-.-.m.-.-.-.-.- .m.m.s.
1.
i i 5 (

Clutch K 1
No. Iescription Qty, T Removing
Note When:
Installing
Special
Instructions
;nap ring X Redetermine

thickness,
if necessary
I(Iuter plate 1 Check for burnt 4.5 or 5.0 mm

spots and bendil “!3 thick (optiona
to adjust play)
nner plate 5 Check for burnt

2.1 mm thick) spots and wear.
If less than 2 mr n
thick, replace.
-
a
Place in ATF
about 1 hour
before installing
w
Iuter plate 4 Check for burnt 3.0 or 3.5 mm

spots and thick
bending (optional to
adjust play)
5 ~Outer plate 1 I Check for burnt

~ 12.0 mm thick) spots and
bending
I IDiaphragm spring Position correct Iv

that curved
surface faces
piston
a I!Snap ring
Special Tool 9315
Install with
Special Tool 93’ 15. I
checking for
correct fit
Diaphragm spring
Spring Vote quantity

for reinstallation
a
Printed in Germany VIII, 1984 Disassembling and Assembling 38-171
Clutch K 1
Special
1
No. Description Qty. Note When:
10 Piston 1 Install with

Special Tools
9317 and 9318
11 Seal 1 I Position correctlv.

coat with ATF ”
12 Seal Position correctly.

coat with ATF
’ 13 Plate carrier
38. 172 Disassembling and Assembling Printed in Germany

Clutch K 1
l
Disassembling
1. Apply Special Tool 9315 on diaphragm

spring and tighten until snap ring can be
removed.
2. Apply Special Tools 9318 and 9317 in

outer plate carrier.
3. Install piston carefully and press into

outer plate carrier without canting.
2. Remove diaphragm spring and springs
Note:
The quantity of springs for clutch piston will

vary. If new springs are required, the same
quantity of springs must be installed.
@
Assembling
1. Install seals in piston that sealing lips face Note:

Coat seals and sliding surfaces on Special
Tools 9318 and 9317 with ATF.
Printed in Germany - VI I I, 1984 Disassembling and Assembling Clutch K 1 38 173

4. Install springs in piston and place on Checking Play (0.7 to 1.2 mm) of Clutch:
diaphragm spring, whereby each spring
must be centered by a guide pin.
1. Push up snap ring around entire periphery
with a suitable screwdriver.
5. Apply and tighten Special Tool 9315.
6. Install snap ring and release special tool.

Check that snap ring fits properly,
t /
7. Install diaphragm spring with curved
surface on piston as shown in figure.
2. Check play “A” with a feeler gauge blade.
1 = Diaphragm spring
8. Assemble set of plates as shown in layout

drawing and install in plate carrier.
a
Note:
New inner plates must be placed in ATF about

1 hour before installing.
38 174 Disassembling and Assembling Clutch K 1 Printed ,n Germanv

Note:
Play “A” can be adjusted with a snap ring

which is available in 3 thicknesses
(2.0 / 2.5 / 3.0 mm). However, if the
specified play cannot be reached with snap
rings, the center outer plates must also be
used for adjusting.
Printed in Germany VIII, ,984 Disassembling and Assembling Clutch K 1 38-175

38
0
TOOLS
1 Assembly tool 9315
3 [ Feeler blade gauge - Standard tool

I

Clutch K 2
0
*-‘-7
r-9-l-l . ,..., i
.
J
a
i 2 3 5

Clutch K 2
T
F
1 Snap ring Redetermine

thickness
if necessary
2 Outer mate Check for burnt 1.5or5.0mm

spots and bending thick
:optional to
adjust play)
3 Inner plate Check for burnt

(2.1 mm thick) spots and wear.
Replace if
thickness is less
than 2 mm.
Place in ATF
about 1 hour
before installing.
4 Outer mate Check for burnt 3.0 or 3.5 mm

spots and thick
bending (optional to
adjust play)
5 Outer plate Check for burnt

(2 mm thick) spots and
6 Snap ring Iqemove with Install with

: ipecial Tool 9315 Special Tool 9315
.I
Check for correct
fit
Diaphragm spring I
I 8 Spring X !N late quantity

fcx reinstallation
19’ Piston 1 Install with

Special Tool
9317
L I !
Printed in Germany VIII, 1984 Disassembling and Assembling 38 179
Clutch K 2
Description ~~~~
Note When: Special
I Removing Instal!ing Instructions
Seal 1 Position correctly,

coat with ATF
11 Sea I 1 Coat with ATF,

I must not turn
on its own
Plate Carrie1 1
38 180 Disassembling and Assembling Pttnted iv Germanv

Clutch K 2
38
Disassembling
1. Apply Special Tool 9315 on diaphragm

spring and tighten until snap ring can be
removed.
2. Install seal in piston that sealing lip faces

2. Remove diaphragm spring and springs
Note:
The quantity of springs for clutch piston will

vary. If new springs are required, the
quantity must not be changed.
3. Apply Special Tool 9317 on plate carrier.
Assembling
1. Install seal and make sure that seal does

not turn on its own.
PrinTed in Germany VIII, 1984 Disassembling and Assembling Clutch K 2 38 181

4. Install piston in plate carrier by turning 6. Apply and tighten Special Tool 9315.
slightly. Do not cant the piston.
7. Install snap ring.
v
,% t A_ 8. Assemble set of plates as shown in layout
4 .*a drawing and install in plate carrier.
Note:
Place new inner plates in ATF about 1 hour

before installing.
Checking Play (0.7 to 1.2 mm) of Clutch:

a
Note: 1. Push up snap ring around entire periphery
with a suitable screwdriver.
Coat seals and sliding surfaces on special tool
with ATF.
5 Install springs in piston and mount

diaphragm spring that each spring is
centered by a guide pin.
38. 182 Disassembling and Assembling Clutch K 2 Prfnted m Germanv

2. Check play “A” with a feeler gauge blade.
Note:
Play “A” can be adjusted with a snap ring

which is available in 3 thicknesses
(2.0 / 2.5 / 3.0 mm). However, if specified
play cannot be reached with snap rings, the
center outer plates must also be used for
adjusting.
Printed in Germanv VI I I, 1984 Disassembling and Assembling Clutch K 2 38 183

928 Differential/Transaxle System 39
TOOLS
a
1 Holder 9216
2 Centering pin 9321

4 Pressing in tool - Made locally (45 x 5 x 40 mm
steel pipe with welded cover
and 11 mm dia. bore)
5 Depth gauge I - Standard iool
a
Printed in Germany VI I I, 1984 Removing and Installing Final Drive 39-101
39 DifferentiaI/Transaxle System 928
REMOVING AND INSTALLING FINAL DRIVE

a
r'-'- .-.- .-.-. - .-.-.-. - .-.-. -.-.- j
14x3- +-I
I
I IL
,, /i,r '2:
i
L3 ,; !j&-;
c
\-1,,’ (-;
!if<>,
18 16 15
1
14 13 1'1 Q
39-102 Removing and Installing Final Drive Printed in Germany

928 Differential, Transaxle System 39
Note when
No. Description Qty. Removing Installing
1 Bolt 4 Torque: 49 Nm / 33 ftlb

2 Washer 4
3 Holder 1
4 Collar nut 1 Torque: 46 Nm / 33 ftlb
5 Nut 1 Torque: 46 Nm/ 33ftlb
6 Washer 1
a Washer 2
9 Final drive 1
10 O-Ring 1 Replace, coat with ATF,

check for correct fit
I1 Shim 5s X Note quantitiy and thick- Redetermine, lf
ness for reinstallation necessary
12 Flange nut’ 1 Engage parking lock and Tighten to 380 Nm I
unscrew 275 Rib and lock
14 Lock washer 6 Hollow side faces flangt
* As of MY ‘92 (Transmission type A 28.18) q 450 Nm (332 ftlb.)
a Removing and installing final drive 39 - 103

Printed in Germany -XxX& 1933
39 Differe”tial/Tra”saxle System 928
NO. Description Qtv Note When: Special

Bearing assembly If necessary. If necessary,

with drive pinion pull out with press in with
suitable puller locally made tool
16 Shim Note quantity Redetermine,

and thickness for if necessary
reinstallation
O-ring Replace.
coat with ATF
18 O-ring Replace,
coat with ATF
19 Automatic 1
I transmission
39 104 Removing and Installing Final Drive Prtnted in Germany

a
REMOVING AND INSTALLING FINAL DRIVE
Removing Installing
1. Remove transmission. 1. Install quantity of shims noted during

removal or shims of redetermined thickness
2. Mount transmission on assembly stand with and bearing assembly on drive pinion.
Special Tool 9216 and drain final drive oil.
3. Engage parking lock and remove collar nut Note:

for drive pinion.
Use centering pins, Special Tool 9321, and a
4. Remove mounting bolts for bearing locally made pressing in tool to make
assembly and pull off bearing assembly installation easier.
(if necessary, use a suitable puller).
m -;--*-- -
& .,’
?=-
,. ,:j?, K! ~--Y-
4
‘..-i’, ; r---3,:, ()I,, iN , (--$q-
k ii
Qf5
,’ \
5 $$ il ’ ‘,\&j/ i 1
- ”
;? .
I- j-1 +& / yb + *’
rem-L ’ !’ /j’
p&p+#; /
.!.
1 = Bolt from Special Tool 9148

A = M 10 x 30 bolt with centering bore 2 = Washer
Printed in Germany . VI 11, 1984 Removing and Installing Final Drive 39-105
2. Tighten flange nut for drive pinion to speci-

a
fied torque and lock by upsetting the flange.
9
a
39-106 Removing and InstallIng flnal drive a

e TOOLS
0 No. Description Special Tool Remarks
1 Pressure pad 9147
I 2 Pin - From P 254
a
Printed in Germanv - VI I I, 1984 Disassembling and Assembling Final Drive 39.107
a
DISASSEMBLING AND ASSEMBLING FINAL DRIVE
I8 8 20 t
: I
J ,‘,~
y;;‘.’7 l5
“Jr; 4/ r
r- dI
1
, \+
2;’ L
,
-X.- a
235 \‘-
4,’ YI. -.. I -_
,
,
,--
IrC
127
Disassembling and Assembling Final Drive Printed in Germany

39-108
-.
1 Bolt 12 Torque:
23 Nm/17 ftlb
2 Washer 12
3 Holder 1
4 Cover 1
5 Gasket 1 Replace
6 Plug 1 Torque:
22 Nm/17 ftlb
7 Plug 1 Torque:
(with magnet) 22 Nmfl7 ftlb
a Shield 1
9 Bolt 2 Torque:
46 Nm/33 ftlb
IO Joint flange 2
I1 Bolt 12 Torque:
23 Nmll7 ftlb
12 Washer 12
13 Holder 1
a I4 Bearing cap 2 Mark for Must be installed
reinstallation same side
2 Replace, coat
with final drive
oil
l
Printed in Germany VIII, 1984 Disassembling and Assembling Final Drive 39 109
‘Jo. Description Qty. Note When: Special

Removing Installing instructions
16 Shim X Note quantity Redetermine,

and thickness if necessary
on each side
for reinstallation
I7 Seal 2 Drive out with a Drive in with

suitable screw- Special Tool
driver 9147
1I8 Tapered roller 2 Mark for Install in same

bearing outer race reinstallation bearing cap.
Heat bearing cap
to 100 “C/212 OF
and drive in with
a suitable pressure
pad
1 I9 Differential 1 Adjust,
if necessary
i !O Vent 1
i !I Case 1
39 110 Disassembling and Assembling Final Drive Printed in Germany

DISASSEMBLING AND ASSEMBLING FINAL DRIVE
1. Clamp final drive in a vise with a suitable 1. Install shield

fixture.
.- - ..
?. ~. s. ‘-
*
k _ L L-, :’ fp+-ff?g-..
f I ,s$;,
_
, ?’ ,-*! ! - -.- rl t - .- I
:t A
I I ’
.- ‘-A,
4 ,.-
MY- _ -.
,6i
A = Iron angle 2. Drive in seal for joint flange with Special

Tool 9147.
~- ~- -
2. Remove bolt for joint flange and take off
flange.
/ ! /--
j bpi.&h AA)
‘\: /;
Printed in Germany VIII, 1984 Disassembling and Assembling Final Drive 39 111
Differential/Transaxle System 39
~~.__ _---- ?
‘I-. -_,
/
: -~ .?q
e..
: \ .) ‘i’ ,,:;
I..-:.
j .( I#-9
1 ‘i f.’ ,
2
2’
i v-+
+ &
1 Pressure pad P 263
3 Pressure pad P 264 b
Printed in Germany - VI I I, 1984 Disassembling and Assembling Differential 39 - 113

l
DISASSEMBLING AND ASSEMBLING DIFFERENTIAL
I 6 3 2
&Y
.< \
’CY ‘<$j?
_ c ,,
z F” ’c 1 (It ” $
9’
qp = .-
I_ 7 1
12 13 lb11 13 12 9 11 1
39 114 Disassembling and Assembling Differential Printed in Germanv

lo. Description Qty. Note When: Special
Removing installing Instructions
1 Tapered roller 2 Pull off with Drive on with

bearing inner race a suitable puller Special Tool
and Special P 264 b
Tool P 263
2 Circlip 1
3 Magnet carrier plate 1
4 ’ Lockplate 6 Replace
- 5 Bolt 12 Threads must

be dry and
greaseless.
Torque:
150 Nm/
108 ftlb
6 Ring gear 1 Tapped holes

for ring gear
bolts must be
dry and
greaseless.
Note pair
number. Adjust
if necessary
7 Pin 1
a 8 Differential pin 1
9 Spacer * 1
IO Needle cage * 2
I1 Small differential 2 Coat oval surface

gear with MoS, paste.
Replace only
in pairs
a Printed in Germany XX, 1988 Disassembling and Assembling Differential 39.115

39 DifferentiaI/Transaxle System
Description Qty. Note When: Special

12 Large differential Coat oval

gear surface with
MoS, paste.
Replace only in
pairs
13 Threaded piece
14 W
15 Differential case
* Modified needle-bearing mount as from Model ‘86. The spacer sleeve is no longer required
thanks to the new needle-roller assembly.
39 116 Disassembling and Assembling Differential Printed in Germany

a
a
DISASSEMBLING AND ASSEMBLING DIFFERENTIAL
Disassembling 2. Coat oval surface of differential gears with

MoS, paste.
1. Pull off tapered roller bearing inner race

with.a suitable puller and Special Tool 3. Install large differential gears with press-
P 263. fit threaded plates through large opening
in differential case and hold with joint
flanges.
Assembling
1. Install ring gear on case and tighten ring

gear bolts to 150 Nm/lOB ftlb. Slide lock-
plate into groove of bolts, squeeze together
at front with a pliers (to unite lockplate
with bolt) and bend down over a hexagon
surface to lock.
a
Printed in Germany VIII, 1984 Disassembling and Assembling Differential 39-117
4. Install small differential gears between large 6. Drive in differential pins to correct
differential gears and turn, until bores of position and lock with key.
gears are aligned with bores in case.
._-
--- r----‘m
e:p I’-*
-- \
‘,.+ .~.3
:
L ~/ CA b?
! ,A-\ ‘-,
f=i “1,
-“d;’ 1: :--z,y 3 C’. .‘;.
f.. ___ * * <.:!I ,.J’ . 1
d ./ -c,, ’
,~
. .-... c.-
,..-:- ._ 7. Drive on tapered roller bearing inner race
with Special Tool P 2546.
‘U
i;
5. Install needle cages and spacer.
-.
,r -
1.~.;.
-
a
39. 118 Disassembling and Assembling Differential Printed in Germanv
a
TOOLS
I+@@& .yh-?
1..A?,*
,.~:
r-7’ PA!!@@
< -f--b , ./
p-4 ,/.~----.
2
/‘“*ah
No. Description Special Tool
1 Puller - e. g. Kukko, size 2
Printed in Germany - VIII, 1984 Disassembling and Assembling 39 119

Bearing Assembly
DISASSEMBLING AND ASSEMBLING BEARING ASSEMBLY
+-
r! T
// ? \‘.~
, ‘p)
f +Y \,x3 l
T \ ?. \a
39-120 Disassembling and Assembling Bearing Assembly Printed in Germany


1 Bearing flange 1 For replacements

only available
as complete part
(positions 1 to 4)
2 Tapered roller 1 Heat to approx.

bearing inner race 120 “C/250 OF
and install
3 Adjusting ring X
4 Tapered roller 1 Heat to approx.

bearing inner race 120 “C/250 o F
and install
5 Pinion 1 Press out with Note pair number.

a piece of Adjust if
suitable pipe necessary
6 O-ring 1 Replace, coat

with ATF
Printed inGermany - VIII, 1984 Disassembling and Assembling 39 - 121

Bearing Assembly
DISASSEMBLING AND ASSEMBLING BEARING ASSEMBLY
1. Press out pinion with a piece of suitable

pipe.
Note:
Bearing flange is only available as a complete

unit (with tapered roller bearings and
adjusting ring) for replacements.
1. Heat tapered roller bearing inner races to

-. - approx. 120 “C/250 OF and install.
i_
2. Press on assembled bearing with a piece of

suitable pipe (approx. 5 tons force).
2. Press off tapered roller bearing inner race 5

with a special tool (e. g. Kukko, size 2).
“-23
fz,-
‘F-7-.-2 ’ .
/I-,--- >-~.
_
39-122 Disassembling and Assembling Bearing Assembly Printed in Germany

3. Lubricate both tapered roller bearings with Use a depth gauge to measure distance from
final drive oil through oil feed bore after tapered roller bearing surface to tearing
installation. flange surface (for example: 34.55 mm).
/,,(
/f9(‘42
Since the design calls for a distance of only
I/,//
34 + 0.05 mm, a shim 0.55 mm thick has to
be used.
$7 II
i( ic-2 . .’
4. If necessary, determine thickness of shims

for bearing assembly.
Example:
34.55 mm actual distance (measured)

Determining Thickness of - 34.00 mm nominal distance (specified)
Shims for Bearing Assembly
0.55 mm thickness of shims
Note:
The adjustment of bearing assembly is

important for axial play of automatic
transmission.
Consequently the thickness of shims has to
be determined again after repairing or
replacing a bearing assembly.
Printed in Germany - VI I I, 1984 Disassembling and Assembling Bearing Assembly 39-123

Determining Thickness of Shims for Bearing
Assembly
0
TOOLS
1 Master gauge VW 385/l

2 Centering plates VW 385/4
3 Master plunger VW 385114
4 Dial gauge extension (30 mm) 9323
5 Adjusting gauge VW 385130
6 Dial gauge - Standard, 3 mm range
7 Dial gauge - Standard, 10 mm range
8 Feeler gauge - Standard, 0.05 to 1 .O mm
9 Clamping sleeve 9145
10 Adjusting fixture VW 52114
11 Master lever VW 388
12 Dial gauge holder VW 387
13 Lever - Made locally
i
PrintedinGermany - VIII, 1984 Adjusting Drive Pinion and Ring Gear 39-125
Recommended Sequence for Adjustment

of Pinion/Ring Gear
If drive pinion and ring gear have to be adjusted, the following sequence of procedures
would be most economical.
1. Determine total shim thickness “Sges” (S, plus S2) for specified preload of tapered roller
bearing/differential.
2. Determine shim thickness “Ss”.
3. Divide total shim thickness “Sges” into S, and Sz, so that specified backlash is between
ring gear and drive pinion.
Objective of adjustments must be to regain the maximum degree of quiet running, as had
been determined by the special testing machine in manufacturing.
Absolute cleanliness is essential for all assembly jobs and testing procedures to guarantee
perfect results.
After working on the final drive it will be necessary to adjust the pinion and ring gear,
if parts had been replaced which have direct influence on said adjustment. The following
chart will help in avoiding unnecessary adjustments!
Ring Gear Drive Pinion Deviation “r

6, + Sz) 63)
Transm. case (automatic) or X

rear transmission case I x
Bearing assembly for pinion X X
Final drive case X X
Side transmission cover X X
Pinion/ring gear X X
Differential case X
Tapered roller bearing for differential X
-,1
0
39-126 Adjusting Drive Pinion and Ring Gear Printed in Germany
ADJUSTING DRIVE PINION AND RING GEAR
General Information
Accurate adjustments of the pinion and ring gear are immensely important for the service
life and smooth running of the final drive. This is why pinions and ring gears are paired
during manufacture and checked in special machines for tooth pattern and quietness in
both directions of rotation. The position of smoothest running is determined by moving
the pinion in an axial direction, whereby the ring gear is lifted out of the no-play meshing
position far enough so that the backlash will be kept with specified tolerances. Deviation “r”
from the adjusting distance called for by design (design distance “R,“) is measured and
recorded on face of drive pinion. Ring gears and pinions are designed so that deviation “r”
is always added to “R”, i. e. is preceded by a + sign.
t
I
l.
873 ate
2 3
R, = Design distance 74.70 mm

r = Deviation from R in l/100 mm
1 = Deviation r
2 = Pair number
3 = Backlash
Printed in Germany VIII, 1984 Adjusting Drive Pinion and Ring Gear 39-127
Changes on Drive Pinion/Ring Gear
Since about January of 1984 manufacturing uses optionally drive pinions/ring gears, on
which a DM value (e.g. DM 75) is recorded instead of deviation “r” (N).
Since this DM value is equal to adjusting distance E (R, + r), the adjusting distance does not
have to be figured out for these drive pinions/ring gears.
-.

E = Adjusting distance
r = Deviation
1 = Adjusting distance (R, + r)
2 = Pair number
3 = Backlash
a
Changes on Drive Pinions/Ring Gears
In the near future there will be drive pinions/ring gears with the following adjusting
information.

E = Adjusting distance
r = Deviation
1 = Adjusting distance (R, + r), e. g. 75.05 mm
2 = Pair number (three digits: 001 999)
3 = Backlash
Note:
The missing 5 mm thick gauge plate VW 385/17 must also be considered for adjustments
with these drive pinions/ring gears.
Example:
Recorded on ring gear - zdjustimj dZttiii& E = 75.05
Adjusting distance E 75.05 mm

Missing gauge plate + 5.00 mm
Adjustment of adjusting gauge 80.05 mm
Printed in Germany VIII, 1984 Adjusting Drive Pinion and Ring Gear 39- 129
39 DifferentiaI/TransaxIe System 928
ADJUSTING PINION
Pinion/Ring Gear Marked “N” Pinion;Ring Gear Marked

” D M ”
On these drive pinion/ring gear sets adjusting
distance “E” is calculated from known design On these drive pinion/ring gear sets “DM”
distance “R,” = 74.70 mm + deviation “r”, is adjusting distance “E”
which is located on face of drive pinion.
1 = Adjusting distance (75.00 mm in

example)
1 = Deviation “r” in l/100 mm 2 = Pair number
2 = Pair number
Note:
Note:
The design of the drive pinion will not allow
The design of the drive pinion will not allow use of the 5 mm thick Special Tool 385/17,
use of the 5 mm thick Special Tool 385/l 7, normally applied for adjustments.
normally applied for adjustments.
Since Special Tool VW 385/30 includes this
5 mm distance, it is important to add 5 mm
Since Special Tool VW 385/30 includes this
to adjusting distance “E”.
5 mm distance, it is important to add 5 mm
to adjusting distance “E”.
Example:
Example: DM 75 is adjusting distance on face of

pinion.
N 18 is the deviation “r” on face of pinion.
DM = adjusting distance 75.00 mm
R, = design distance 74.70 mm Missing special tool + 5.00 mm
r = deviation + 0.18mm
Adjustment of master 80.00 mm
E = adjusting distance 74.88 mm
gauge
Missing special tool + 5.00 mm
Adjustment of master 79.88 mm
gauge
39 130 Adjusting Drive Pinion and Ring Gear Printed in Germany

1. Install bearing assembly with shims and 8. Install second side bearing cover without
tighten collared nut to 380 Nm/275 ftlb. O-ring and secure with two bolts.
2. Install final drive case (without shims) 9. Pull out centering plate of master gauge
and tighten all bolts or nuts to 46 Nm/ with the spindle that master gauge can
33 ftlb. s&II just be turned by hand.
3. Install one side bearing cover without

O-ring and secure with two bolts.
4. Adjust setring of Special Tool VW 385/l

to distance “a”.
10. Set Special Tool VW 385/30 to adjusting

distance “E” + 5 mm (for missing Special
Tool VW 385/l 7).
a=39mm
5. Slide Special Tools VW 385/4 on to 385/l,

Install Special Tool VW 385/14 with dial Example:
gauge extension 9323.
R,= 74.70 mm
r = + 0.18 mm
E = 74.88 mm
+ 5.00 mm
79.88 mm adjustment of
master gauge
6. Turn pinion that surface of collared

nut is vertical.
7. Insert master gauge into case.
Printed in Germany VIII, 1984 Adjusting Drive Pinion and Ring Gear 39 131
39 DifferentiallTransaxle System 928
Example: Note:
DM=E 75.00 mm The measured value will always deviate from

+ 5.00 mm the set distance in clockwise direction
80.00 mm adjustment of (small needle of dial gauge will be between
1 and 2). i. e. when adjusting the dial gauge
master gauge
with 1 mm preload the value deviating from
1 is added as shim thickness .&.
Il. Install master gauge and set (3 mm

range) dial gauge at zero with 1 mm
preload. 13. Install the determined shim thickness
S3 between transmission case and final
drive case.
14. Recheck distance after installation of

p”r shims with determined thickness.
.w/ p- A deviation of ? 0.03 mm is permissible.
‘/ ’
,e I i
h! g &,’ ;.;
a;“;
,’ i!~$$=-&~r L “:-
a*i. ” ‘F
12. Turn master gauge carefully until dial

gauge extension is vertical to face of drive
pinion head. At this moment dial gauge
needle will reach its point of reverse
direction, at which dial gauge must be
read.
a
39.132 Adjusting Drive Pinion and Ring Gear Printed in Germany
ADJUSTING RING GEAR (Sges)
1. Clamp final drive case in a vise, using a 5. Check gap between transmission case
and side transmission cover with a feeler
gauge,
A = L-iron bar 6. Calculate shim thickness Sges.
Sges. = gap - 0.30 mm (bearing preload)
2. Install differential with ring gear in

case.
Example:
3. Install side transmission cover (ring gear Gap 1.25 mm

end) without shims and tighten all Bearing preload - 0.30 mm
hexagon head bolts to 23 Nm/17 ftlb.
Sges. 0.95 mm
4. Guide in second side transmission cover

without shims carefully.
Printed in Germany - VIII, 1984 Adjusting Drive Pinion and Ring Gear 39 - 133
ADJUSTING BACKLASH
1. Place shims determined for pinion adjust- 6. Engage parking lock.

ment between transmission case and final
drive case. Install final drive case and
tighten all mounting bolts to specified 7. Turn rinq__oear carefully by hand against
torque of 46 Nm/33 ftlb. stop and set dial gauge to zero.
2. Install differential in case. Hold drive pinion with locally made hook
and turn back ring gear carefully. Read
and note amount of backlash.
3. Install side transmission cover, using total
shim thickness “Sges” as determined on
ring gear end and tighten all hexagon
bolts to 23 Nm/17 ftlb.
4. Turn differential in both directions several

times, to settle tapered roller bearings.
5. Install measuring tools. Set Special Tool

VW 388 to distance “a” = 80 mm.
Hook made locally from flat iron 30 x 5 mm

DETERMINATION OF SHIMS S, AND Sz
Measured backlash must be brought to value Determining Shim

specified by manufacturer of pinion/ring Thickness S,
gear by splitting total shim thickness Sges. (Opposite Ring Gear)
Backlash required is stamped on ring gear. S2 = Sges -S,

Adjusted backlash value could be less by
0.05 mm, but must never be greater than the
stamped value. Example:
Sges 0.95 mm
S, - 0.27 mm
0.68 mm
Determining Shim
Thickness S,
(Ring Gear End)
Note:
S1 = Sges (total shim thickness) On the basis of experience with these

- measured backlash pinions/ring gears the shims S2 (opposite
ring gear) can be selected approx. 10 to 15 %
+ backlash inscribed on ring gear
thinner in favor of shims S, (ring gear end).
1. Remove side transmission cover and split

Example: total shim thickness Sges, that it gives
the determined shim thicknesses S, and
s*
Sges 0.95 mm
- measured backlash 0.88 mm
0.07 mm Note:
+ inscribed backlash 0.20 mm
(by way of example) When tightening nuts for side transmission
0.27 mm covers, always remember that there is a
S,
certain amount of backlash.
Never let the drive pinion and ring gear
clamp.
Printed in Germany VIII, 1984 Adjusting Drive Pinion and Ring Gear 39 - 135
2. Measure backlash and, if necessary, change

shims S, and Sz again until specified play
is reached.
3. Check backlash at four places on periphery.

turning ring gear by 90” each time.
Measurements must not deviate from each
other by more than 0.05 mm.
a
DISASSEMBLING AND ASSEMBLING CENTRAL TUBE
6
7
Printed in Germany - VI I I, 1984 Disassembling and Assembling 39 -137

Central Tube
39 Differential,transaxiesystem 926
Nite when:
No. Designation Qty. Removing Replacing
1 Pan-head screw 1 Tighten only after driver

plate (5) has been fitted
to flywheel. Tightening
torque: 80 Nm
2 Circlip* 1
3 Sleeve’ 1
4 Shim’ X
5 Driverplate 1
6 Pan-head 1 Torque: 20 Nm
7 Spring washer 1
8 Hex bolt 4 Torque: 45 Nm

9 Spring washer 4
IO Clutch housing 1
I1 Cover 1
I2 Sleeve 2
I3 Sleeve 2
I4 Central pipe 1 prijfen ggf. erneuern
Parts are deleted as of MY ‘85. Adjustment of the driver plate (including pre-1985 models) is no a
longer required.
39 - 138 Removing and installing central tube (autom. transmiss.) a

Printed in Germany - XXIX,1992
Checking Central Tube
Note: 3. Small corrections can be made by

tapping face of central shaft with plastic
Replace entire central tube with shaft and hammer.
bearings, if bearings and/or shaft are damaged.
There are no replacement parts available,
1. Check easy movement of central shaft

bearings by turning shaft by hand. Shaft
must turn easily and without restriction at
any point.
2. Position of central shaft and rear flange

shaft is important to guarantee proper
function.
Distance between central shaft and rear
flange must be A = 2 * 0.5 mm.
Printed in Germany VI I I, 1984 Checking Central Tube 39 139

a
Adjusting Drive Plate
To avoid axial pressure on crankshaft and crankshaft thrust bearings, the connections
between flywheel and drive plate (distance X) must be checked and adjusted after replace-
ment of engine, flywheel or central tube. This adjustment is not necessary after replacement
of transmission or transmission oarts.
1 - Circlip
2 ~ Bushing
3 - Holding flange
4 - Drive plate
5 - Central shaft
6 - Engine flywheel
7 - Preload 0.3 + Cl.2 mm
A-Distance A, engine flange/flywheel mating surface
X-Shim thickness (must be determined again)
Printed in Germany VI I I, 1984 Adjusting Drive Plate 39 - 141

Determining Distance “X” Example:
Measured value 52.5 mm

1. Crankshaft must contact thrust bearing Gauge thickness - 40.0 mm
toward the rear. Use a lever to press Distance “A” 12.5 mm
flywheel in direction of transmission, until
axial play of crankshaft is eliminated.
3. Mount transmission on central tube to

specified torque. Screw in clamping
sleeve mounting bolt by hand (do not
tighten).
4. Push drive flange with bushing, but without

shims, on to central shaft and install
circlip.
5. Use a suitable lever and push central shaft

on drive flange far enough forward, that
central shaft rests on rear clamping screw
in shaft groove.
2. Determine distance “A”, by using 9211

and measuring distance from engine 6. Tighten rear mounting bolt for clamping
flange to flywheel mating surface. sleeve to 75. 85 Nm/54. 61 ftlb.
7. Push drive flange forward against stop

on circlip and tighten bolt.
8. Determine distance “B”. Use 9211 and

measure distance from clutch housing to
drive plate bearing surface (as far in as
-
possible).
Note:
Mark thickness of gauge when measuring.
39 - 142 Adjusting Drive Plate Printed in Germany

Note:
Mark thickness of gauge used for measuring.
Example:
Measured value 45.4 mm

Gauge thickness - 40.0 mm
Distance B 5.4 mm
Determine distance “X”
0 X = A - B + 0.3 mm preload
A= 12.5 mm
B= - 5.4 mm
7.1 mm
Preload + 0.3 mm
x= 7.4 mm
Install shim having thickness X

(in example 7.4 mm).
a Shims are available in thicknesses

0.5 mm and 1 .O mm.
of 0.2 mm,
Tighten mounting bolt for front drive flange

only after central tube has been installed,
Printed in Germany - VI l I, 1984 Adjusting Drive Plate 39 143

Diffarantiil, transaxle system 39
PSD diagnosis / Troubleshooting
PSD = Electronically controlled Porsche limited-slip differential
PSD diagnosis/Troubleshooting D39 - 201

Printed in Germany - XXXV, 1995
39 Differential, transaxle system 926
Contents
Test point Title Page
PSD layout ..__._.._____...__...............................,..,,,,....,,,,..,..,,,..,,..,,..,,.,,,..,.,,,,. D39-202a

Component layout _____..__....__._.._....,....,,,.....,,,,..,,,.....,,,,....,,,,.....,,,..,,,,,,....,,,,. D39-202b
PSD - fauit display I troubleshooting procedure __,__,,,,....,,,,..,..,,,....,........... D39-202c
Bleeding condition of lock control .,,..,,._..._....___................................,,........., D39-202d

(Re-bleeding lock operating hydraulics I point 2 on P. D39-202d)
Measuring plate wear of controlled limited-slip differential .__..__..__._..,.._..,,,

D39-202e
Checking locking torque (friction coefficient) of transverse lock ..__.....D39-203
Checking pilot pressure valve in the lock hydraulics (lock operation) .. .. . . . . ..D39-215
5 Lateral acceleration sensor (mounting/testing) D39-219
6 PSD - Diagnosis with system tester 9288 . . .. .. . . . . . . . . . . . . .. . . .. . . . . . . . . D39-223
7 Checking lock hydraulics.. ............................................................................ ,D39-247

Pressure test on lock hydraulics .................................................................... D39-251
Replacing the pressure warning switch ......................................................... D39-257

Replacing the pressure reservoir.. ................................................................. D39-259
a
D39 - 202 PSD diagnosis/Troubleshooting
Printed in Germany - XXXV. IBSS
0
PSD layout
1 - ABS I PSD control unit 5 - Lock solenoid valve*

2 - Lateral acceleration sensor 6 - Pressure reservoir
3 - Slave cylinder, transverse lock 7 - Supply tank*
3a- Pilot pressure valve in lock hydraulics 8 - Wheel speed sensor
4 - Pressure pump with pressure warning switch”
l The lock hydraulics (No. 4 to Wb. 7) is located on a joint bracket in the lefl-hand
wheel well. Brake fluid is used as the operating medium.
Further infonation on P. D39-247.
PSD diagnosismroubleshooting D39 - 202a

Printed in Gemmy - XXXV. ,996
Component layout
ABS I PSD control unit Lock hydraulics

The control unit is located in the driver’s foot- The lock hydraulics is accessible in the let%
well - near the A-pillar - above the front cover hand rear wheel housing afler removal of the
opening handle, wheel housing cover.
Lateral acceleration sensor Voltage supply, lock hydraulics

The sensor is mounted on a welded-on Voitage supply for the lock hydraulics (energy
bracket below the let&hand seat. production) is via a fuse and a relay. The re-
lay and fuse are located in the spare-wheel
well.
D39 - 202b PSD diagnosis/Troubleshooting a

Printed in Germany - XXXV, ,998
PSD - Fault display / Troubleshooting procedure
Fault display Troubleshooting procedure
If the ABWPSD control unit detects a fault in Read out the DTC memory with system tester
the electronically controlled limited-slip dif- 9288 and remedy the fautt if necessary.
ferential (PSD), the PSD is swkched off for This is described on Page 039-223 ff.
safety reasons and the following fautt display
appears in the display fields of the information
system: If only the PSD is switched off (ABS OK) and
no fault is stored in the ABS/PSD DTC me-
moly, the fauit lies in the lock hydraulics (ener-
PSD OFF gy production).
The PSD is always switched off when the

ABS (antilock braking system) is switched off.
Note
The PSD indicator lamp (green lamp) in the
instrument cluster lights up while the lock is
active.
a PSD diagnosis/Troubleshooting D39 - 202~

Printed in Gemmny - XXXV, 1996
Bleeding hydraulics of Porsche controlled limited-slip differential (PSD)
Preparatory work:
0 Remove rear left inner fender.

0 Connect bleeding device to PSD hydraulic reservoir
0 Disconnect vent line (if present).
0 Build up bleed pressure (approx. 1.5 - 2.0 bar).
1. Bleeding the pressure reservoir.
To charge the pressure reservoir, the ignition must be switched on.

When the pressure reservoir has been charged, the pump cuts out; reservoir pressure is then ap
prox. 180 bar.
0 Connect the bleed cylinder.

a Switch off the ignition.
a Carefully open the bleed valve and allow the pressure level to drop gradually.
While this is being done, the ignition must remain switched off to ensure that the pressure is
completely reduced and the air is expelled from the reservoir.
0 Repeat this procedure several times, making sure that the ignition is switched on/off at the ap-
propriate stages in the procedure.
2. Bleeding the valve block and the locking line to the lock slave cylinder
0 Connect the 9288 system tester.

0 Switch the ignition “ON”.
l Connect the bleed cylinder to the bleed screw on the slave cylinder.
0 Open the bleed screw on the slave cylinder.
0 Select “Start PSD Bleeding” and actuate repeatedly until no further air emerges,
l The bleeding device must remain switched on, because the reservoir volume is used up rapidly.
0 After this, close the bleed screw on the slave cylinder.
a Select “Stop Bleeding” and “Start Pressure Reduction” on the system tester.
a Switch off the bleeding device and disconnect it.
0 Screw on the reservoir cover.
a Open the vent line at the reservoir again (if present).
D39 - 2026 PSD diagnosis/Troubleshooting 0

Printed in Gsmwmy - XXXV. 1996
l Check level in the reservoir. The fluid must be approx. I cm above the step in the reservoir body
or between the markings (with the pressure reservoir charged).
Measuring the plate wear on the controlled-slip differential
Note
The wear dimension can be determined only
by means of the measuring cylinder - special
tool 9514.
1” Remove slave cylinder.
Note
In order to avoid venting of the lock system,
the pressure line at the slave cylinder must
not be disconnected when the transmission is
installed. In this case, unflange the slave cylin-
der with pressure line from the housing.
LS = Measuring range for longftudinal lock

911 Carrem 4
2. Back off the adjusting screw of the measu-
ring cylinder as far as possible (this faci-
QS = Measuring range for transverse lock
litates assembly of the cylinder).
928 S4,
m GT. 929 GTS and 911 Carrera 4
3. Mount the measuring cylinder on the trans-
1 - Spacer tappet
mission and tighten the knurled nut.
2 - Adjusting screw
Note
If the transmission is installed, it is recommen- 2a - Measuring groove on adjusting screw
ded to use two studs M8 x 45 with continuous
thread to secure the measuring cylinder. 3 - Knurled nut
Note
4. Screw in the adjusting screw on the measu-
When the wear dimension has been reached,
ring cylinder until there is no longer any
the plates of the lock must be replaced. Do
adal play at the spacer tappet. Read off the
not correct the wear dimension at the thrust
wear dimension in this position.
bearing under any circumstances.
New dimension = 34.5 mm

Wear dimension = 45.0 mm
l PSD diagnosisrkoubleshooting D39 - 202e

Printed in Gemnny -xXx& 1996
Checking locking torque (friction coefficient) of transverse lock
Tools
r
9
I-
.183-D
a PSD-Diagnosis I Troubleshooting D39 - 203

Printed in Germany - XXVII, 1991
No.
T Special tool Explanation
Pressure gauge 9509 000.721.950.90

High-pressure measuring line 9509/l 000.721.950.91
Ring flange 999.215.027.02
Banjo bolt 930.110.547.00 shorten threads by

approx. 4 mm
Seal NO138112 2 PC.
Union 950913 000.721.950.93
Torque adapter plate 951 O/l 000.721.951 .Ol
Support block 9509/4 000.721.950.94 1 pc.
Self-disengaging commercially availa-

torque wrench (click wrench) ble (refer to shop ma-
covering a range of 5 Nm nual). Depending on
(4 ftlb) to 500 Nm (369 ftlb) the type of torque
wrench used, corre-
sponding reduction
pieces or adapters
are required for con-
nection to the adapt-
er plate
(No. 7).
System Tester 9288 9288 000.721.928.80
with
connecting hose 9288/i 000.721.928.81
and
corresponding 928DV 000.721.928.D’/.001 German
program module 928GV 000.721.928.GV.OOi English
(act. to language used) 928FV 000.721.928.FV.OOf French
928lV 000.721.928.1\1.008 Italian
928EV 000.721.928.EV.001 Spanish
928SV 000.721.928.SV.001 Swedish
928JV 000.721.928.JV.OOE Japanese
D39 - 204 PSD-Diagnosis I Troubleshooting

Printed in Germany - XXXV, 19%
Important notes
Check with cold transmission. Parking brake released, no gear engaged.
When checking the locking torque, it is not the rotating torque (starting torque) but rather the
breakaway torque that is measured. For this reason, self-disengaging torque wrenches must be used.
Checking
a Procedure I Execution / Notes
1. Carry out general preparations

according to right-hand column Remove rear wheels
- Fit torque adapter plate (Special Tool 951011) with

original wheel bolts to left-hand rear wheel hub.
- Remove rear M-hand inner wheel arch panel
Prepare self-disengaging torque wrenches (click

wrenches) covering a range of approx. 5 Nm (4 fllb)
to 500 Nm (369 ftlb). To fit them to the torque
adapter plate, suitable reduction pieces or adapters
are required.
a PSD-Diagnosis / Troubleshooting D39 - 205

Procedure Execution 1 Notes
2. Prepare vehicle for transverse

lock measurement.
Proceed as follows: - Remove rear left-hand brake caliper.

Remove rear left-hand brake caliper Place the support block (arrow) into the brake
(do not open hydraulic brake system) caliper, replacing the brake disc. Place brake
and place support block Special caliper on rear axle trailing arm or suspend in
Tool 950914 into the brake caliper, a suitable place.
replacing the brake disc.
- Connect pressure gauge to
transverse lock cylinder.
- Connect System Tester 9266 to diag-

nosis socket.
- Bleed pressure gauge. To keep the
reservoir level from dropping too far
(low volume), connect a bleeder unit
to the reservoir. Bleeding pressure
approx. 1.5 to 2.0 bar. The venting
line remains clamped.
D39 - 206 PSD-Diagnosis / Troubleshooting a

a
Procedure Execution I Notes
~~~~~~~~~
- Connect ring flange (No. 3) to measuring line

(No. 2). Proceed by fitting this assembly, complete
with banjo bolt, seals and fitting (Nos. 4, 5 and 6).
to the transverse lock slave cylinder, replacing
the bleeder valve.
Important note
Tighten Nos. 4 and 6 carefully and use a second
wrench to lock when tightening, making sure the
parts do not bind. If this is not observed, the fitting
(No. 6) may shear off. Pilot pressure is normally
present at the bleeding valve (No. 6). Open valve
slowly before removing it (to allow the pressure level
to be dumped slowly)
l PSD-Diagnosis / Troubleshooting D39 - 207

Execution / Notes
+
- Connect high-pressure measuring line (No. 2) to

pressure gauge (cf. arrow) and suspend pressure
gauge (No. 1) in rear left-hand wheel housing area
so that it may be read off easily.
Bleed pressure gauge by connecting the bleeding
device to the PSD reservoir. Clamp venting line.
Build up bleeding pressure (approx. 1.5 to 2.0 bar).
Connect System Tester 9288 along with adapter
line 9288/l to diagnosis socket (located next to the
passenger’s seat under the booster cover).
Clock lock solenoid valve complete with System
Tester 9288 in “Drive links / Bleed position” menu
and allow brake fluid to escape at the bleeder valve
(No. 1 a) until it is free from air bubbles. (Use collec-
tor bottle).
Close bleeder valve and press stop button. Select
pressure reduction position.
Switch off bleeding device.
D39 - 208 PSD-Diagnosis / Troubleshooting l

3. Perf. transverse lock measurement - Observe testing conditions indicated in opposite

(locking torque to pressure ratio) column
- Switch on System Tester. Select “Check transv.

Testing concl. I important information
lock”
- Transmission cold / parking brake
released, no gear (driving position) - Fully close transverse lock by applying approx.
selected 20 pulses (gauge pressure =140...180 bar).
Pressing operating button at tester once = 1 pulse
- Before starting measurements,
close lock once for a short time - Switch to pressure release position and start with
(activate full pressure) measurement no. 1
- To measure the locking torque, - Measurement 1 = gauge pressure 0...5 bar

rotate only in forward direction! Set torque wrench to approx. 5 Nm and use
Always measure across adapter adapter plate to connect to left-hand rear wheel
plate at left-hand rear hub hub (No. 7). Observe clicking direction of torque
wrench.
- Lock right-hand rear wheel fully
While performing measurements, actuate service
using the service brake
brake to ensure that the right-hand rear wheel is
- Measure breakaway torque / locking fully locked. Turn torque wrench carefully (i.e.
torque at the specified test pressures avoiding jerks) in forward direction.
using the torque wrench. Do not jerk If the wheel hub does not yet rotate when the
when rotating. Advance carefully torque wrench clicks the actual locking torque has
from bottom (low value) lo top not yet been reached.
until the breakaway torque / lock- Adjust torque wrench to higher value and repeat
ing torque is reached. operation.
- Establish test pressures using The actual locking torque (actual value) is achieved
System Tester 9288, clocking the when the wheel hub turns and the moment when
transverse lock solenoid valve. the torque wrench starts to click is just about
(Drive links /Check transv. lock menu) reached.
II the wheel hub turns but the wrench does not yet
click, the torque set at the wrench is too high
Test pressures / measuring process (actual locking torque is lower).
Measurem. 1
= press. between 0...5 bar
Measurem. 2=” ” 10...20 bar
Measurem. 3=“ ” 20...40 bar
Measurem. 4
= breakawaytorque
500 Nm (369 ftlb) mini-
mum, with pressure held
at 60 bar or above
Measurem. 5 = check pilot pressure
transverse lock. Specified
value approx. 3.0...4.5 ba

Printed in Germany . XXVII, 1991
Differential. Transaxle Svstem 928
Procedure Execution / Notes
Refer to page D39-213 for a listing of When measuring the breakaway torque, measure at
the actual values (admissible locking several locations (angular positions) within one wheel
values) vs. the corresponding revolution.
pressures.
After the actual locking torque has been reached,
Possible causes for deviation from immediately read off the pressure at the pressure
specification gauge. Record both actual values
- Test requirements not met. (torque + pressure).
Example: RH rear wheel not fully
locked, pressure gauge and lock
hydraulics not properly bled. - Measurement 2 = Gauge pressure IO...20 bar
Use the System Tester to build up test pressure,
- Faulty discs
applying a corresponding number of pulses.
Hydraulic pressure does not become Set torque wrench to bottommost value (depending
effective to the degree indicated at on pressure) according to boundary value window
the discs, e.g. due to faulty setting of (p. 039.213).
the mating bearing screw of the en- Repeat process as described for measurem. no. 1.
gaging lever (engaging lever rides).
- Measurement 3 = Gauge pressure 20...40 bar.
Repeat process as described for measurements
1 and 2. respectively.
- Compare actual values obtained in measurements

l/2/3 with values specified on p. D39-213.
039 - 210 PSD-Diagnosis / Troubleshooting a

928 Differential. Transaxle Svstem 39
Example:
Measurement 2 = Gauge pressure lo...20 bar
Actual values: Gauge pressure = 13 bar,

locking torque measured = 240 Nm (177 ftlb)
Specified value according to table at 13 bar:

120...300 Nm (88...221 ftlb)
Measurement 2 o.k. since results are within the

tolerance band (boundary value window)
- Measurement 4 = Minimum locking torque of

500 Nm (369 ftlb) must be
ensured. Equivalent pressure
60 bar or higher
- Measurement 5 = pilot pressure valve

Proceed to pressure release position and read off
pressure at gauge. Specified value: approx.
3.0...4.5 bar. If measurements are out of limits,
repeat process, starting from low pressure max.
20 bar. In this case, release pressure by switching
off ignition.
a PSD-Diagnosis / Troubleshooting D39- 211

Differential. Transaxle Svstem 928
4. With the System Taster switched off

I Execution I Notes
- Open measuring line and transverse lock cylinder

(to ensure that only pilot pressure is carefully (observing pilot pressure). Remove
present at the measuring line), measuring line and fit bleeder valve.
remove pressure gauge complete
- Bleed transverse lock using System Tester 9288,
with connecting lines.
with bleeding device connected to reservoir and
Install bleeder valve and bleed
switched on (vent line clamped off).
transverse lock.
Follow by correcting reservoir level (to a level
Correct reservoir fluid level.
between MIN and MAX mark) with accumulator
fully charged.
Screw on reservoir lid, open vent line at reservoir
again,
- Check hydraulic lines for outside leaks, controlling

5. Check lock hydraulics for leaks. full system pressure at lock cylinder using System a
Disconnect System Tester. Tester 9288.
Install rear brake caliper.
- Then disconnect System Tester.
- Tighten brake caliper mounting bolts to

85 Nm (63 ftlb).
6. Fit rear left-hand wheel housing

inner panel. Fit rear wheels.
Take vehicle for a short test drive
(to check lock and brake operation).
039 - 212 PSD-Diagnosis / Troubleshooting l

928 Differential. Transaxle Svstem 39
Locking torque-to-pressure limits
Locking torque (Nm) (ftlb)
Pressure (bar)

92s Differential, Transaxle System 39
Checking pilot pressure valve of lock hydraulics (lock operation)
General
Normally the pilot pressure valve is checked within the scope of measuring the friction coefficient of
the transverse lock (test item 3).
A pilot pressure valve (arrow) is located ahead of the transverse lock slave cylinder on the left-hand
transmission side.
If pilot pressure is too high, squeal noises may result. Due to wear and vehicle dynamics constraints,
zero pilot pressure is also to be avoided. When replacing components, do not confuse with the
PDAS pilot pressure valves designated for the 911 Carrera 4.
Specifications / identification of the pilot pressure valves
Type Specification Identification

I
911 Carrera 4 ~ approx. 2.0 to 3.5 bar 2 3 stamped on valve
929 with PSD ~ approx. 3.0 to 4.5 bar 3 - 4 stamped on valve
PSD-Diagnosis I Troubleshooting 039 - 215

Checking pilot pressure valves
1. Prepare vehicle for pilot pressure - Connect ring flange (No. 3) to measuring line
valve check. (No. 2). Proceed by fitting this assembly complete
with banjo bolt, seals and fitting (Nos. 4, 5 and 6),
Operations: to the lock cylinder, replacing the bleeding valve.
Connect high-pressure measuring line (No. 2) to
- Connect pressure gauge to lock pressure gauge.
slave cylinder.
Important note
Connect System Tester 9288 to
Tigthen Nos. 4 and 6 carefully and lock when
diagnosis socket.
tightening, making sure the parts do not bind.
- Bleed pressure gauge. If this is not observed, the fitting (No. 6) may
shear off.
D39 - 216 PSD-Diagnosis / Troubleshooting a

928 Differential. Transaxle Svstem
- Connect System Tester 9288 along with adapter

line 9288/l to diagnosis socket (located next to the
passenger’s seat under the booster cover).
Bleed pressure gauge by clocking lock solenoid
valve complete with System Tester in “Drive links /
Bleed position” menu and allow brake fluid to es-
cape from the pressure gauge at the bleeder valve
until it is free from air bubbles. (Use collector bottle).
For this purpose, leave bleeding device connected
to reservoir and leave bleeding line clamped. Bleed-
ing pressure approx. 1.5 - 2.0 bar.
Close bleeding valve and press stop buttom. Select
pressure reduction position.
Switch off bleeding device.
Important note
2. Check pilot pressure valve opera-

If pilot pressure is too high (before replacing a valve),
tion as described below:
build up a lower pressure and reduce pressure by
Use System Tester 9288 to activate
switching off the ignition, thus deviating from the
transverse lock solenoid (Drive links /
previous testing procedure.
Check transv. lock menu) with 1 - 2
Pilot pressure may drop by max. 0.2 bar within
pulses.
5 minutes.
Then switch to pressure reduction
position and read off gauge pressure
after a short interval (to allow for
gauge damping).
- After disconnecting the pressure gauge, use the
For specifications, refer to
System Tester (Drive links Select bleeding
p. D39-215.
menu) and allow brake fluid to escape at bleeder
valve of the transverse lock slave cylinder until fluid
3. Follow check by bleeding the
is free from air bubbles.
transverse lock and correcting the
reservoir level. - Correct reservoir level with accumulator fully
charged (after pump unit has switched off automat-
ically). Do not fill above “max. mark”.
Screw on reservoir lid. Open venting line at reser-
voir again. Disconnect System Tester.

Lateral acceleration sensor
Installation position Installation
The lateral acceleration sensor has been The sensor is fastened onto a welded-in sup-
installed on a support welded in under the LH port (2 bolts). The correct installation position
seat. (sensor in horizontal position) will be obtained
The sensor is required for the electronically automatically, if the welded-in support has not
controlled limited slip differential. been deformed.
If the support has been deformed (due to an
accident), it has to be readjusted using a
bubble level:
For this purpose, park the vehicle on level
ground.
After installation, check the sensor for proper

functioning.
Checking
Notes on checking
Checking relates to the following aspects:
-correct installation position of the sensor

Important notes
The sensor must not be exposed to extreme - sensor function

accelerations which may, for example, be
caused by throwing, falling down or shocks.
After an accident, the sensor must always be

checked. If the sensor is out of specifications,
it has to be replaced.
Lateral acceleration sensor D39 - 219

Printed in Germany - XXXIV. 1994
Differential, Tansaxle System
The 55-pin ABS 2 LED adapter lead (see item r

I), a multimeter, a shop trolley jack and a
measuring tape are required for this test. The
55-pin adapter lead required to run an ABS
test on the Carrera 4 (964) and the 928 with
PSD (instead of the %-pin adapter lead) has
3 outputs incorporated for testing the longitudi-
nal and lateral acceleration sensors.
The longitudinal acceleration sensor is only
fitted to the Carrera 4 (964).
Manufacturer of the adapter lead:
Robert Bosch GmbH

Dept.: KHiVKD 2 2. With the vehicle in normal position, check
Postfach 41 09 50 and record the voltage reading at the lateral
D-76225 Karlsruhe acceleration sensor (with the ignition
Phone: 0721/942-O switched on).
Fax: 0721/9422187 Specification: 2.7 + 0.14 volts.
Normal position means: Vehicle must be on
Supplier of the adapter lead: a level surface. If the vehicle was off the
ground before the test, slacken the suspen-
Authorized dealer sion if required (move vehicle a few yards
Part No. KDAS 000317 and jounce from and rear ends of vehicle
several times).
If the reading deviates from the specifica-
1. With the ignition switched off, take off the tion, continue with the assessment table
ABSIPSD control unit connector and con- at the end.
nect it to the 55.pin ABS 2 LED adapter lead.
Note
The following tests can be carried out with or
without the ABS 2 LED tester being connected.
The 3 outputs are identified by special symbols
A = Signal of longitudinal acceleration sensor

B = Signal of lateral acceleration sensor
C = Ground contact for both sensors
D39 - 220 Lateral acceleration sensor

Printed in Germany - WXIV. 1994
3. Establish a ground clearance of approx.

150 mm at the left front wheel by liffing the
vehicle at the left front jacking point. Read
off and record sensor voltage value.
4. Lower left front side of vehicle. Then raise

vehicle at the front right end in the same
manner by approx 150 mm. Read off and
record sensor voltage value.
5. Assess readings according to the below

table. Correct any faults that may be present.
Lateral acceleration sensor D39 - 221

Printed in Germany XXXN, 1994
Assessment table for sensor tests
Test item I Requirements

Notes Fault I Troubleshooting
Sensor installation position - Specified reading:

via output voltage 2.7 f 0.14 volts when the vehicle is on a level surface
(ignition is switched on).
The sensor is supplied
with an input voltage of If the reading exceeds or falls below the specification, this
5 volts across the ABS /PSD means that the sensor bracket is bent or that the sensor is faulty.
control unit. The output volt-
age is 2.7 volts, provided that If no voltage is displayed, the wiring has gone open circuit, the
the sensor is in a horizontal sensor is faulty or an incorrect socket was used at the test lead.
position and fully operative. Check wiring rouring according to wiring diagram if requried.
Some faults (open circuit I short circuit, sensor fault) are stored
in the fault memory of the ABS/PSD control unit. The fault mem-
ory (in PSD system) must therefore be read out with System
Tester 9288 and erased after the fault has been eliminated.
Sensor operation - Specified display:

Based on the initial reading, the voltage must be higher when
To test, raise vehicle once at the left side is raised and lower when the right side is
front right and once at front left raised.
by approx. 150 mm in each
case. Example:
Initial reading 2.65 V
This must result in an exactly Raised at front left 2.85 V
predefined change of the volt- Raised at front right 2.46 V
age.
Use the above measurement If the voltage does not change when the vehicle is raised (by
(initial reading obtained with the same amount on left and right), this means that the sensor
vehicle on level surface) as a is faulty.
reference. Read out fault memory (in PSD system) with System Tester
9288 after eliminating the fault and erase the fault memory as
required.
D39 - 222 Lateral acceleration sensor

Printed in Germany XXXIV. 1994
920 Differential. transaxle svstem 39
PSD - Diagnosis with system tester 9288
General information
The PSD/ABS control unit is suitable for self-

diagnosis. This means that the control unit
can detect, store and output certain faults of
the PSD and the ABS.
Diagnosis is performed with system tester

9288 in combination with the adapter lead
9288/l and the corresponding module (depen-
ding on the language in question).
The diagnosis socket is located next to the
passenger’s seat underneath the booster co-
ver. Positive potential is permanently connec-
ted to the PSD/ABS control unit in order to
prevent detected and stored faults from being
deleted when the ignition is is switched off.
PSD diagnosis is not possible with the engine

running.
Overview of available PSD menus
1 = DTC memory
2 = Drive links
1= DTC memory see Page D39 - 226
2= Drive links
Bleeding see Page D39 - 202d

Checking the transverse lock
see Page D39 203

Printed in Germany XXXV. 1995
39 Differential, trsnsaxle system 926
Connector pin assignment for control unit (PSDIABS)
1 - Voltage, terminal 15 IO - Speed sensor output at rear light for RDK

(tire pressure monitoring system) control
2 - Operation of ABS rear-axle solenoid unit
valve
11 - Vottage, terminal 30
3 - Ground, ABS solenoid valve, front tight
12*- Speed sensor output at rear lefl for
4 - K wire from diagnosis RDK control unit”
5 - Operation of pump motor relay on hydrau- 13 - Free

lit unit
14 - Free
6 - Free
15 - Voitage supply (+5V) for acceleration sen-
7 - Operation of valve relay on hydraulic unit sor
8 - Free 16*- Speed sensor output at front right for

RDK control untt’
9 - Ground of acceleration sensor
l additionally for vehicle speed. PIN 16 (fmnt lefl) on mod. 199111992. PIN 12 (rear lefl) as of
mod. 1993.

a
Printed in Germany XXXV. 1886
17 - Monitoring, vottage supply for ABS so- 37 - Ground, ABS solenoid valves, front let? +
lenoid valves rear axle
18 - Free 36 - Free
19 - Operation of ABS solenoid valva, front left 39 - Free
20 - Vottage for valve and motor relays on hy- 40 - Indicator lamp (green) for PSD function
draulic unit
41 - Free
21 - Operation of transverse lock solenokl valve
42 - Ground, shield, speed sensor at rear right
22 - Operation of ABS solenoid valve, front
right 43 - Signal, speed sensor at rear right
23 - Monitoring of voltage supply for lock so- 44 - Gmund, shield, speed sensor at rear tefl
lenoid valve
45 - Signal, speed sensor at rear lefl
24 - Operation of ABS warning lamp
46 - Ground, shield, speed sensor at front right
25 - Free
47 - Signal, speed sensor at fmnt right
26 - Free
48 - Ground, shield, speed sensor at front lefl
27 - D + (Terminal 61 / charge)
49 - Free
28 - Free
50 - Signal, speed sensor at fmnt left
29 - Brake light switch
51 - Free
30 - L wire from diagnosis
52 - Electronics ground
a 31 - Pump motor monitoring
32 - Free
(hydraulic unit)
53 - Speed sensor output at front right for RDK
control unit
33 - Free 54 - Free
34 - Signal from lateral acceleration sensor 55 - Free
35 - Operation of instrument cluster: PSD off
36 - Free
l PSD diignosisfkoubleshooting
Printed in Germany W, 1666
D39 - 225
DTC memory
Overview of the possible faull displays
E,.,
DTC 5%: Speed sensor, DTC
rear right
sssssssssssssssssssssss 23
El,,
/-.-
§§a Speed sensor,
rear left
24
18: Latsral acceleration 55: ABS valve,

sensor, front left
signal implausible
sssssssssssssssssssssss 13 sSssssssssssssSssssssss 31
55: Transverse lock, ssr As.9 valve,

front right
deviation
ssssSsssssssSssssssssss 14 sssssssssssssssssssssss 32
5%: Control unit 55: Ass valve,

defective rear axle
sssssssssssssssssssssss I15 sssSssssssssssssSssssss 33
I
55: Speed sensor, 5%: Valve relay
front left
sssssssssssssssssssssss 21 sssssssssssssssssssSsss 34
5%: Speed sensor, 5%: Return pump

front right
sssssssssssssssssssssss 22 1 sssssssssssssssssssssss I35
D39 - 226 PSD diagnosismroubleshooting

a
Printed In Germany XXXV, ,666
a
Fault overview/Troubleshooting (diagnosis/test plan)
Test point DTC Fault display (short fault text) Page
1 11 Transverse lock valve D39 - 230
2 12 Lateral acceleration sensor, D39 - 232

short circuit/discontinuity
3 13 Lateral acceleration sensor, D39 - 233

signal implausible
14 Transverse lock, deviation D39 - 234
15 Control unit defective D39 - 235
6 21 Speed sensor, front left D39 - 236
7 22 Speed sensor, front right D39 - 236
8 23 Speed sensor, rear right D39 - 236
9 24 Speed sensor, rear left D39 - 238
10 31 ABS valve, front left D39 - 238
11 32 ABS valve, front right D39 - 240
12 33 ABS valve, rear axle D39 - 240
34 Valve relay D39 - 241
. :: 35 Return pump D39 - 245
PSD diagnosiflroubleshooting D39 - 227

0 Printed In Germany XXXV. 199s
DTC memory / Troubleshooting
Important notes Combined plug connections - distinguish-

ing between wires
If warning displays light up and/or faults are
shown in the DTC memory of the PSD/ABS, In the brake pad wear, speed sensor and HF
they may also have been triggered by the fol- sending unit wiring there are several com-
lowing problems: bined plug connections of similar pattern. In
this area, the wires can be distinguished as
- Control unit supply voltage less than 9.5 follows:
Volt (undervottage)
- Shielded wires for the speed sensors and
- Control unit plug disconnected. HF sending units.
- Contact resistance caused by poor - 2 wires with a protective tube for brake
ground connections. leading to differen- pad wear.
ces in potential or inadequate shielding of
speed sensors. The poor ground connec- - One pin and one socket exist on the HF
tion may not only occur at the affected sending unit plug connections. The speed
components, but also at other important sensor plug connections possess 2 pins
grounding points. as well as 2 sockets on the opposite side.
- ImpottankThe warning “PSD off’ may ap - Two combination connectors are located
pear in the display fields of the instrument one above the other in the spare tire
cluster, even though no fault is stored in area. The wires are identified there with
the DTC memory. Check the lock hydrau- L = rear lefl and R = rear right.
lics (lock operation) in this case (as of
Page D39-247).
Troubleshooting aids
When measuring with the multimeter at the

control-unit plug, make up 1 or 2 auxiliary
leads in your own workshop, each with 2 flat
pin plugs No. 17.457.2, to avoid damaging
the plug contacts in the control-unit plug du-
ring the test.

Printed in Germany XXXV. IDS6
l
Replacing the hydraulic unit
After installing/bleeding the ABS hydraulic

unit, carry out a complete ABS test with the
ABS 2-LED tester.
Test-drive after eliminating the fault.
Clear the DTC memory after eliminating the

fault. Perform a test drive and then read out
the DTC memory again.
If necessary (e.g. in the case of a fault in the
speed sensors), also clear the DTC memory
of the RDK control unit.
PSD diegnosieiTroubleshooting D39 - 229

Printed In Germany XXXV, 1495
Fault, DTC Possible causes, remedy, notes
Test point 1
Transverse lock valve No feedback signal from valve to control unit.
DTC tl
1. Switch off the ignition. Pull the plug off the control unit.
Check that circuits at plug are not interrupted.
PIN 21 to PIN 23
PIN 21 to PIN 17
If necessary, interrupt the wiring path (plug on transverse lock

solenoid valve) and localize the discontinuity by reference to the
wiring diagram.
2. Pull off valve relay (No. 1) on the hydraulic unit. (Remove wheel
housing cover at the front-lefl side),
Check for a short circuit to plus or ground in the wiring path, as
described in point 1, by measuring at PIN 21.
If there is a fault in the wiring path, separate it as described in
point 1 so that the unwanted connection to the positive or nega-
tive side can be located.
a
Printed in Gemuny - XXXV, IS96
“i~:.~easra~~o~~amo~~e~~~f,t~o~~~o~s~~ob~-~e~
For this purpose, disconnect the plug connection on the trans-
verse lock solenoid valve (armw). The transverse lock solenoid
valve is located beneath the rear lefl wheel housing cover.
Nominal value X.4 R between the PINS on the valve block.
Nominal value not OK: Replace the transverse lock solenoid valve.
4. Check that the valve relay is energized (voltage present at so-

lenoid valves of ABS and PSD).
Connect all plugs and the relay for this purpose. Push back the
protective tube on the transverse lock valve plug (in the wheel
housing on the rear lefl).
Switch off the ignition, then switch k on again,
Battery voltage must be present at the black wire.
If no battery voltage is present: Continue with test point 13/DTC

34 (valve relay). Note testing instructions (see below).
If voltage is present, by replacing the PSD/ABS control

unit (output stage defedive).
Notes on testing
If a plug for the power supply to the solenoid valves (ABS or differen-
tial lock) is detached while the ignition is switched on, the valve relay
is de-energized. Even if the plug is then reconnected, the relay will
not be re-energized until the ignition has been switched off and on
again.
PSD diagnosismroubleshooting D39 - 234

Prtrhd in Germany - xxxv. 1886
Fautt, DTC Possible causes, remedy, notes
Test point 2
Lateral acceleration Wiring between control unit and lateral acceleration sensor not in
sensor, short-circuit/ working order (discontinuky. short circuit to plus or short circutt to
ground), or the lateral acceleration sensor itself is damaged.
discontinuity
The following wiring is installed:
DTC 12
- Power supply to sensor (5 Voit) =
PIN 15 at control unit - PIN 3 at sensor
- Ground for sensor =
- Signal from sensor to control unit

(2.7 f 0.14 Volt with car in normal-load position) =
1. Check power supply (approx. 5 Volt) at the sensor plug after de-
taching it, with the ignition switched on. PIN 1 (-) and PIN 3 (+).
Note
The sensor is located under the let&hand seat.
2. Check for discontinuity or short circuit to ground at the wire

between PIN 2 at the sensor plug and PIN 34 at the control unit
plug after this has been detached.
3. Conned the plug to the sensor. Check the installation poskion of
the sensor and its function by testing the output signal. To make
this check, connect the %-pin ABS 2-LED adapter lead to the con-
tmt unit plug. Connect the multimeter to sockets B and C.
For the measuring procedure and nominal Values, see Pages
D39-219...D39-222.

Printed in Gemumy - XXXV. reo6
a
Test point 3
Lateral acceleration Signals from lateral acceleration sensor to control unit are incorrect.
sensor, signal implausible The sensor has a mechanical defect or its installation position is in-
correct.
DTC 13
I. Check lateral acceleration sensor,
Pages D39-219 .,. 039-222.
2. Replace the sensor if necessary. No repair work on the sensor is

permitted.
3. Afier eliminating the fault, repeat the test.

Printed in Gemuny - XXXV. IBM
l
Test point 4
Transverse lock, During the transverse lock regulating phase, the monitoring circuit in
deviation the PSD/ABS control unit has identified excessive variations be-
DTC 14 tween the nominal and actual values.
Possible faults
- Lock control circuit poorly bled (lock operation hydraulics)
- Lock hydraulics leaking
- Lock solenoid valve has a mechanical defect
- Lock cylinder does not retain preset pressure (leaking through re-
lief bore)
- Inadequate signal from a rear wheel speed sensor
- Fault in transverse lock plates
- Insufficient hydraulic pressure builds up at plates, e.g. because

thrust-bearing bolt of engaging lever is wrongly adjusted (enga-
ging lever makes contact).
Procedure
I. Check lock hydraulics for external leaks. Replace defective parts
if necessary.
2. Repeat bleeding procedure for lock control circuit (lock hydrau-

lics). If new parts have been installed, the lock must be bled as ap
propriate (Page D39-202d).
3. Check speed sensor signals (Pages D39-236 . ..D39-238).
4. Measure thickness of plates with lock measuring cylinder (special

tool 9514). Page D39-202e.
5. Check pressure at locking torque (friction value of the lock)

(Pages D39-203...D39-213).

Printed in Gummy - XXXV, IS96
Test point 5
Control unit defedive Before replacing the control unit, check whether:
DTC 15 - there is any electrical interference from the ignition voltage (for ex-
ample, if the spark plug caps are not correctly attached)
- them are any differences in potential caused by contact resistance
(missing or poor ground connections).
Important:
A poor ground connection may occur not only at the affected compo-
nents but also at other important grounding points.
- ground contact is present at control unit plug PINS 3, 52 and 37.
These wires are connected to ground point IV or V (at the steering
console in the case of left-hand drive vehicles I over the central
electrical system in the case of right-hand drive vehicles).
Important
When replacing the PSD/ABS control unit, make sure that if is not
confused with the PDAWABS control unit from the 911 Carrera 4
(964).
Distinguishing feature on P. 039-236.
PSD diagnosisilroubleshooting D39 - 235

Printed in Gsmny -XXX”, 1986
Test point 6
Fmnt lefl No signal from speed sensor reaches control unit, or signal is incorrect
wheel sensor I unrealistic.
DTC 21
Important: This fault is also indicated if the PDAWABS control unit for
the 911 Carrera 4 (964) is installed.
If assembly work has already taken place, check that the correct con-
trol unit has been installed.
Distinguishing feature: part number,
928 control unit with PSD = 928 618 .,, __

911 Carrera 4 control unit = 964 618 ,..
1
/--
I. Pull off the control unit plug. Measure the internal resistance I
check continuity between PIN 50 and PIN 48 on the
plug.
Nominal value 600...1600 R.
If the nominal value is not attained, check the wires and plug con-
nections in the circuit from the front left speed sensor.
If the nominal value (600...1600 n) is not attained although the

wires I plug connections are in working order, replace the speed
sensor.
Important: Perform measurement directly on the speed sensor be-
fore replacing the sensor.
B-P-e-e-e-z-e-e-:-e m D * * n * ” * -
~~~~
9 ~ a-8-3-P-‘-“-‘-“-“-F-9-4-1
a
Prtntsd in Gcmny - XXXV. ISM
2. Checking the speed sensor signal.

For thts check, use the ABS 2-LED tester or an oscilloscope.
Connect the ABS 2-LED tester to the control unit plug with the
55-pole adapter lead.
If an oscilloscope is used, separate the speed sensor plug connection
at the wheel suspension or on the spring strut dome in the engine
compartment (see Page D39-228 for distinguishing features for
wires).
Connect the oscilloscope to the plug at the speed sensor side.
Depending on the tester, select special input or secondary screen.
Check by turning the lefl front wheel by hand.

ABS tester in program switch position 6 I rotary switch for wheel
selection to front-lefl wheel. Turn the wheel until the LED (No. 2)
lights up without flickering.
If an oscilloscope is used, turn approx. 1 revolution per second.
Nominal values I nominal display
ABS 2-LED tester = > 2.0

Oscilloscope = sine wave > 2 Vott
(measured value: peak to peak)
Possible causes of deviations:

- Air gap at speed sensor too large I too small
(check installation).
- Pulse wheel damaged or corroded
-Wheel bearing play too large

Printed in Germany - XXXV. lS95
Test point 7
Front right General procedure as for DTC 21 (test point 6)
speed sensor 1. Internal resistance / continuity between PIN 47 and PIN 46 at control
unit plug.
DTC 22
2. Speed sensor signal: If the ASS tester is used, turn the wheel
selector switch to the front right wheel.
Test point 8
Rear right General procedure as for DTC 21 (test point 6)
speed sensor 1. Internal resistance/continuity between PIN 42 and PIN 43 at control
unit plug.
Rear left
2. Speed sensor signal: If the ASS tester is used, turn the wheel
selector switch to the rear right wheel.
Test point 9
Rear left General procedure as for DTC 21 (test point 6)
speed sensor 1. Internal resistance / continuity between PIN 44 and PIN 45 at control
unit plug.
DTC 24
2. Speed sensor signal: If the ABS tester is used, turn the wheel
selector switch to the rear left wheel.
Test point
Front left
10
Certain faults in the ABS valve area (short circuit to plus or short circuit
a
ABS valve to ground in a control wire) can also be shown as a valve relay fault
by the 9288 system tester.
DTC 31
A fault in the ABS valve circuits is normally stored as an
ABS valve fault in the DTC memory of the control unit.
When the DTC memory is read out, it is possible in the above situation
for two faults to be displayed (ABS valve and valve relay).

Printed in Germany - XXXV, 1995
1. Switch off the ignition and pull the plug off the control unit. Check
PIN 19 of plug to PIN 17 and to PIN 23 for continuity.
If necessary, interrupt the circuit (plug at hydraulic unit) and localize
the discontinuity by reference to the wiring diagram.
2. Pull off the valve relay (7-pole) at the hydraulic untt.

Check for a short circuit to plus or to ground in the circuit as de-
scribed in point 1 by measuring at PIN 19.
If a fault is detected, interrupt the circuit as described in point 1 in or-
der to localize the incorrect short-circuit to plus or to minus.
3. Check resistance between PIN 19 of the plug and terminal 30 at the

valve relay.
lf nominal value is obtained: proceed with point 4.

If nominal value is not obtained:
Pull off the 12-pole plug at the hydraulic unit.
Check internal resistance of the AES solenoid valve. Measure
between PIN 1 and PIN 4 (at the hydraulic unit).
Nominal value 0.7...1.7 0.
If nominal value is incorrect: replace the hydraulic unit.

Printad in G-ny -XXXV, 1886
4. Check whether the valve relay is energized (voltage is present at the

solenoid valves).
To make this check, connect all plugs and the relay. Push back the
protective tube on the transverse lock valve plug (in the wheel hous-
ing at the rear leff).
Switch the ignition off, then on again.
If no voltage is present: continue with DTC 34 (valve relay). Comply
with the testing notes.
If voltage is present, try replacing the PSDIABS control unit (output
stage defective).
Testing notes
If a voltage supply plug to the solenoid valves (ABS valves or diffe-
rential lock) is pulled off while the ignition is switched on, the valve
relay will be de-energized. It is not re-energized when the plug is re-
conneded until the ignition has been switched off and on again.
a
Test point 11
Fmnt right Comply with note under test point 10: Front lefl ABS valve (DTC 31).
ABS valve DTC 32
When troubleshooting, proceed as for DTC 31, but use PIN 22 instead
of PIN 19 on the control unit plug.
To check the internal resistance of the ABS valve (atler pulling off the
12-pin plug at the hydraulic unit), measure between PIN 3 and PIN 4
(instead of PIN 1 and PIN 4).
Test point 12
Rear axle Comply with note under test point 10: Front lefl ABS valve (DTC 31). 0
ABS valve
For troubleshooting, proceed as for DTC 31, but use PIN 2 instead of
DTC 33
PIN 19 of the control unit plug.
To check the internal resistance of the ABS valve (afier pulling off the
12-pin plug at the hydraulic unit), measure between PIN 5 and PIN 4
(instead of PIN 1 and PIN 4).
a
Printed in Germany -XXXV, ,666
a
Test point 13
Valve relay Certain faults in the ABS valve area (short circuit to plus or short circuit
DTC 34 to ground in a control wire) may also be shown as valve relay faults
by the 9286 system tester.
A fault in the ABS valve circuit is normally stored as an
ABS valve fault in the DTC memory of the control unit.
In the case described above, when the DTC memory is read out the
display of two faults is possible (ABS valve and valve relay).
1. Switch off the ignition. Pull off the control unit plug.
Check the control circuit (wire with relay) - from PIN 20 to PIN 7 - for
any discontinuity, short circuit to ground and shod circuit to plus.
lf no fault is found, proceed with 2.
If there is a discontinufty, short circuit to plus or short circuit to

ground, pull off the valve relay. Check the wires between terminal 85
on the relay base and PIN 7 on the control unit plug and between ter-
minal 66 and PIN 20.
If the wires are in working order, replace the valve relay.
a
PSD diagnosis/Troubleshooting 039 - 241
Printed in Germany - XXXV, I666
2. Measure resistance between the following PINS at the control unit

plug:
PIN 19 to PIN 17
PIN 22 to PIN 17
PIN 2 to PIN 17
Nominal value approx. I...2 n
PIN 21 to PIN 23
Nominal value approx. 2...4 .Q
If the nominal value is conect, proceed with 3.

If incorrect values are obtained, localize the fault as appropriate.
From PINS 19. 22, 2 to PIN 17 = ABS valves + wiring.
From PIN 21 to PIN 23 = Lock valve + wiring.
Re ABS valves + wires

Pull off the IZpole plug at the hydraulic unit.
Measure the internal resistance of the solenoid valves.
PIN 1 to PIN 4
PIN 3 to PIN 4
PIN 5 to PIN 4
Nominal value approx. 0.7...1.7 n
Nominal value not obtained: replace hydraulic unit.
a
Printed in Gemuny - XXXV. 1996
a
Re transverse lock valve + wiring:

Separate plug connection at the transverse lock valve (arrow).
Measure internal resistance of the solenoid valve.
Nominal value 2...4 n
If an incorrect value is obtained: Reolace transverse lock valve
3. Pull off valve relay (i’-pole) at hydraulic unit. Measure at control unit
plug PIN 17 in order to determine whether there is a short circuit to
plus or to ground.
If necessary, interrupt the circuit at the hydraulic unit plug (12-pole)
and localize the fault by reference to the wiring diagram.
4. Check whether voftage is present at terminal 87 of the relay base
when the valve relay is pulled off. Required display: approx. 12 Volt
(battery voltage).
5. Measure resistance between terminal 87 a on the relay base and
the ground wire at the pump motor.
Nominal value a 2...4 R. The prerequisite is here is that the ground
wire and the gmund point are in working order.
If necessary, replace the hydraulic unif (resistance in relay base has
increased in value).
a
Printed in ‘3em”ny -XXX”, 1996
6. Check wires from terminal Ll on the relay base

to PIN 24 on the control unit plug and
from L2 to PIN 35 for discontinuity.
Important: The test from L2 to Pin 35 can be performed only if the

warning contact of the pressure warning switch is closed (see wiring
diagram).
This means that the pump for the lock hydraulics must have opera-
ted beforehand (system pressure greater than 140 bar).
7. Check that the valve relay is energized (voltage present at the so-
lenoid valves).
Connect all plugs and the relay.
Push back protective tube on the transverse lock valve plug (at the
rear leff in the wheel housing).
Switch the ignition off, then switch it on again.
a
If no voltage is present, try replacing the valve relay, or test the relay
with the ABS 2-LED tester in order to detenine whether it is
actually defective.
If the LED of the ABS tester fails 7
to light up steadily in program
switch position 5 with the ignition LE3 II+-
switched on, the relay is defective.
8. If the valve relay is in working order, try replacing the PSD/ABS wn-
trol unit (output stage defecfive).
a
PrInted in Germany - XXXV, ,996
Test point 14
Return pump, 1. Switch off the ignition. Pull off the plug at the control unit. Check
DTC 35 control circuk (wire with relay) - PIN 20 to PIN 5 - for discontinuity
and short circuit to groundtto plus.
If no fault is found, proceed with 2.

If there is a discontinuity, short circuit to plus or to ground, pull off
the motor relay. Check wiring between terminal 65 at the relay base
and PIN 5 on the control unit plug, and between terminal 66 and
PIN 20.
If the wiring is in working order: Replace the motor relay
2. Pull off the motor relay. Battery voltage (appmx. 12 Volt) must be
present at terminal 67 of the relay base.
3. Bridge terminals 30 and 87 at the relay base.

If the return pump does not run, continue wYh 4.
If the return pump runs:

Check wire from terminal 30 on the relay base to PIN 31 at the con-
tml unit plug. If the wire is in working order: Replace the motor relay.

Printed in Germany - XXXV. 1996
4. Check connections at ground wire (1) and plus wire (2) (contact re-
sistance).
Bridge terminals 30 and 87 at the relay base and check whether volt-
age is present at the connection point (3).
If voltage is present (but the return pump is not running): Replace
the hydraulic unit (defective return pump).
0
D39 - 246 PSD diagnosisfkoubleshooting
Printed in Gemuny - xxxv, ,996
Check lock hydraulics (energy production)

General information
The hydraulics comprises the high-pressure pump, solenoid valve, pressure reservoir and supply
tank. The components are located on on a joint bracket in the rear-left wheel housing.
The brake fluid for operating the transverse lock is obtained from the piston reservoir mounted on
the high pressure pump. The operating pressure is between 140 and 180 bar. The pump is activated
via a pressure warning switch.
The solenoid valve familiar from the ABS system controls the functions pressure increase, pressure
maintenance and pressure reduction, and applies pressure to the slave cylinder of the transverse
lock.
Important note
Check hydraulics of the lock (energy production) if “PSD off” appears in the display fields of the in-
strument cluster even though no fault is stored (following pages).

Printed in Germany - XXXV. 1995
Check hydraulics of the lock Troubleshooting

This comprises: check of the lock hydrau- If the system is depressurized, the follo-
lics without pressure gauge (special tool wing faults are possible:
9509).
- Brake fluid reservoir (No. 12) empty
(system leaks).
Precondition
- Voltage supply for high-pressure pump
Read out DTC memory with system tester
(No. 1) not OK (check pump relay No. 38
9288. No fault stored.
and fuse in the luggage compartment).
1. Jack up the vehicle on one side until a rear
- Pressure warning switch (No. 2) not OK.
wheel can be turned freely.
Test on Page D39-251 ff.
- High-pressure pump (No. 1) defective.

2. Switch on system tester 9288. Select lock
Check pump operation by bridging terminals
test (system PSDl Drive Links menu).
30 and 87 on the pump relay (in the lug-
gage compartment).
Pulse transverse lock (pressing function key Important: Pump operating time when brid-
I on tester once = 1 pulse) and simulta- ging the terminals max 3 seconds. (Per-
neously turn the rear wheel. form test only once.)
- Mechanical defect of lock solenoid valve

The wheel must be completely fixed (No. 9).
(locked) after several pulses.
Caution: If the vehicle is fully raised, hold
The following faults are possible if system
the opposite rear to keep it from turning.
pressure is present:
- Pressure warning switch (No. 2) not OK
If the wheel does not lock, continue with
troubleshooting “System depressurized”. - Electrical wire for activating the fault display
If the wheel does lock, continue with trou- “PSD off not OK (check in combination
bleshooting: System pressure present. with the wiring diagram).
- High-pressure pump no longer operates (de-

fect, or voltage supply not OK), but there is
still a residual pressure of less than 107 bar
in the system. This pressure is reduced
each time the pump is operated.

a
Printed in Gemny - XXXV,1985
a
Important note
If the pressure warning switch (No. 2) and / or the pressure reservoir (No. 5) is detached with the
high-pressure pump (No. 1) removed, do not set down the pump upside down (with the pressure
reservoir connection facing down). If this is not observed , the pump might not function after instal-
lation (air in the pump). Fast turning or shaking motions from thr normal position might make the
pump operational again.

Printed In Germany - XXXV, 1995
a
Tools
345/l-D3W5
No. Designation Special tool Order number Explanation
1 Pressure gauge 9509 000.721.950.90
2 High-pressure measuring 9509/i 000.721.950.91

line
a 3 Ring flange 999.215.027.02
4 Banjo bolt 930.110.547.00 shorten threads by

approx. 4mm
5 Seal N 013 811 2 2 pc.

Printed in Germany - XXXV, ,996
Pressure tests on the lock hydraulics (energy production)
Overview
1. Genera
2. Pressure gauge connection
3. Tests
4. Nominal values/Notes
1. General
The following points can be checked by
means of the pressure test on the differential
- Connect pressure gauge 9509 - in combina-
lock hydraulics (lock control):
tion with the high-pressure measuring line
9509/l (No.~), ring connection (No. 3). ban-
- Freedom from leaks of the lock hydraulics
jo bolt (No. 4) and two seal rings (No. 5) -
(any internal leak can thus be localized)
at the lock solenoid valve instead of the
bleeder valve.
- Gas filling pressure of the pressure reservoir
Important: Machine ring connection (No. 3)

- Switching points for the lock hydraulics (di-
beforehand (apply face/arrow).
splay “PSD off” and operating pressure).
This is controlled by the pressure warning
switch of the pump assembly.
2. Pressure gauge connection

- Depressurize the lock hydraulics. To do
this, disconnect the electrical plug at the
pressure pump (pump assembly) and then i
relieve the pressure at the pressure relief
valve of the lock solenoid valve (use a col-
lection bottle).
L
Important: Wear goggles and protective
gloves, as the pressure may be as high as
180 bar.
D39 - 252 PSD diagnosisfkoubleshooting

a
- Bleed pressure gauge (No. 1). To do this, 3. Tests

connect a collection bottle to the pressure
gauge bleeder valve (No. la) and open the Note
valve.
Operation of the pump is regulated by means
Turn ignition key to position 2 (necessary
of the ignition key for testing purposes.
for pump operation).
Plug the electrical plug onto the pump. Di-
Position 0 = Pump off
sconnect the electrical plug and close
Position 2 = Pump on until switched off by
the bleeder valve as soon as no air bub-
the pressure warning switch.
bles are visible anymore in the transparent
bleeder line of the collection bottle.
Make sure that the brake fluid reservoir is
not sucked empty. Fill in brake fluid from
time to time if necessary.
a
Depressurize the lock hydraulics before re-
moving the pressure gauge after the test.
- In ignition key position 0, plug the electrical

plug onto the pump. Locate the pressure
gauge in a position where it can be seen.
For the tests, it is expedient to observe the fol-

lowing sequence:
. . 1
a. Pressure reservoir - gas filling pressure
b. Switching points for the warning display

“PSD off”
c. Cut-in and cut-out points of the pump
d. Leak test
- Turn the ignition key to position 2 (pump

starts up).
a PSD diagnosisfkoubleshooting D39 - 253

a
a. Gas filling pressure of the pressure reser- c. Checking the switching points of the
voir. pressure pump
Turn the ignition key to position 0 at approx. Cut-out pressure: Turn the ignition key to po-
100 bar. Briefly open the bleeder valve on the sition 2. The electrical plug must be plugged
pressure gauge (use collection bottle) and onto the pressure pump for this.
close it again immediately. The pressure drop Read off the pressure on the pressure gauge
on the pressure gauge should be approx. immediately after the pump cuts out automat-
5 bar. Continue this process in intervals. The ically.
pressure reservoir gas filling pressure has
been reached at the instant the pointer of the Cut-in pressure: Turn ignition key to position
pressure gauge abruptly falls to 0 bar. 2. Wait until the pump cuts out automatically
Refer to Page D39-255 for nominal values. if necessary. Carefully reduce the system
pressure at the pressure gauge bleeder valve
(use collection bottle) until the pump cuts in
Important: Always wear goggles and pro-
again. Read off the pressure on the pressure
gauge at this moment. Refer to Page D39-
255 for nominal values.
b. Checking the switching points for the

warning display in the instrument cluster. d. Checking the tightness (pressure loss)
of the lock hydraulics.
Turn the ignition key to position 2. Wait until
During pressure increase: the pump cuts out automatically. Carefully lo-
Start the engine and observe the warning di- wer the system pressure at the pressure
splay. Immediately turn the ignition key to 0 gauge bleeder valve (use collection bottle)
position at the instant the warning display until the pump cuts in again. After the pump
(PSD off) goes out. Read off the pressure on cuts out automatically, turn the ignition key to
the pressure gauge. position 0 and disconnect the electrical plug
at the pump. Measure the pressure decrease
over time.
During pressure reduction
The permissible values are given on Page
Produce a system pressure of approx. D39-255.
140 bar.
Disconnect the plug at the pressure pump. Note
Start the engine.
Reduce the pressure - in a similar manner to Depressurize the lock hydraulics before re-
the procedure described in Gas filling press- moving the pressure gauge.
ure of the pressure resewoil - until the war-
ning display (PSD off) lights up. Read off the
pressure on the pressure gauge. Refer to
Page D39-255 for nominal values.
0
Printed In Germany - XXW, 1995
4. Nominal values/Notes
Nominal values Notes
Pressure reservoir - Gas filling pressure Replace pressure reservoir if the gas filling pres,
new 80 + 5 bar sure has reached or fallen below the wear limit
wear limit 40 bar
Switching points of the pressure warning If the actual values deviate from the nominal val-
switch ues, replace the pressure warning switch.
PSD off Warning point
up to approx. 115 bar
max. up to 133 bar
sure reductrnn as of 105 + 2 I - 5 bar
Cut-out point of the pump Read off the pressure immediately after the pump
at the latest at approx. 160 bar cuts out automatically.
at the earliest at approx. 160 bar
Cut-in point of the pump
(after pressure reduction) 140 + 5 / - 6 bar
Freedom from leaks of the lock hydraulics Fill the pressure reservoir completely 2x pre-
Pressure reduction, starting from the cut-out viously (start the pump running again after the 1st
point of the pump (precondition: the nominal cut-out operation by opening the bleeder valve on
value has been achieved) the pressure gauge). Use a collection bottle.
Then turn the ignition key to position 0 and di-
not below 140 bar in 30 minutes sconnect the electrical plug at the pump.
not below 100 bar in 3 hours mleak:Retighten lines or replace the corre-
sponding parts.
Possible internal leaks:

Refer to Page D39-256
a PSD diagnosiflroubleshooting D39 - 255

Nominal values Notes
- Lock solenoid valve

- Pump assembly
First check the lock solenoid valve. Then remove
the pressure line from the pump assembly (with
the system depressurized).
Connect high-pressure measuring line 950911
(No. 2) -without ring connector - to the pump
assembly.
Repeat the test. If the nominal values are now

achieved, replace the lock solenoid valve.
If the nominal values are not achieved, the fault
lies in the pump assembly.
Replace faulty parts and bleed the system.
Caution: Wear goggles and protective gloves
when reducing pressure via the bleeder valve.
0
Prlnled In Germany - XXXV, 1995
Removing and installing pressure Installing

warning switch of lock hydraulics
1. Screw in the pressure warning switch (No.
2) and tighten to a torque of 26 Nm (19 fl-
lb). Replace the O-ring if necessary. Pre-
‘I. Wtih the ignition key in position 0, pull off vent the pump assembly from turning while
both plugs at the pump assembly. tightening the pressure warning switch.
2. Completely depressurize the system. To do Note

this, slowly open the bleeder valve on the
lock solenoid valve and drain the brake fluid Wet the sealing ring with brake fluid only.
Never use brake cylinder paste. Absolute cle-
into a collection bottle.
Important: The system is under a press- anliness is essential. Use only lint-free clea-
ure of up to 180 bar. Wear goggles and ning cloths.
protective gloves.
3. Remove pressure warning switch (No. 2) 2. If there is an electrical fault at the pressure
with special tool 9524. Prevent the pump as- warning switch, always replace the hydrau-
sembly from turning while loosening the lic pump relay (in the luggage compartment)
switch. as well.
Important: First clean the area around the
pressure warning switch and cover it with
lint-free cleaning cloths to trap the small
amount of residual brake fluid that emerges.
12
i I
a PSD diagnosiwTroubleshooting D39 - 257

Printed in Germany - XXN, 1996
Differential, transaxle svstem 928
3. Attach plug to pressure warning switch 5. If necessary, connect pressure gauge -

(plug on the pomp side remains discon- special tool 9509 -to the pressure reservoir
nected at this point). and check the switching points of the pres-
sure warning switch and also for leakage in
the differential lock hydraulics.
The exact work procedures and nominal
values are stated on Pages D39-251 -
D39-256.
If necessary, top up the brake fluid level at in-

tervals so that the brake fluid reservoir is not
drained completely. The lock hydraulics must
be at zero pressure when connecting and re-
moving the pressure gauge.
6. Afler the testing and assembly work has

2389-039
been completed, correct the brake-fluid le-
vel when the pressure reservoir is fully
4. Partially bleed the lock hydraulics as follows: charged.
Wfih the ignition switched on, open the blee-
der valve on the lock solenoid valve. Attach
the electrical plug to the pump, As soon as
brake fluid emerges free from air bubbles.
pull off the electrical plug and close the blee-
der valve.
Next, charge the pressure reservoir com-
pletely. To do this, attach the electrical
plug. As soon as the pump is heard to
switch off, pull off the electrical plug and
reduce the pressure at the bleeder valve of
the lock solenoid valve. Slowly open the
bleeder valve and hold the bleed hose firmly.
Important: A pressure of up to 180 bar is
present in the system. Wear goggles and
protective gloves.
0
Printed in Germany - XXXV. IN6
Removing and installing the press-

ure reservoir
Removal
1. Pull off plug on the pump motor with the
ignition key in position 0.
2. Completely depressurize the system. For

this purpose, slowly open the bleeder valve
on the lock solenoid valve and drain the
brake fluid into a collection bottle.
Important: The system is under a press-
ure of up to 180 bar. Wear goggles and
protective gloves.
i
Installation
1. Screw in the pressure reservoir (No. 5) with

new O-Ring (No. 4) and carefully tighten it
using a universal filter wrench (tightening
torque 40 46 Nm; damage is possible
above a torque of approx. 70 Nm).
Neverturn the filler screw when instal-
ling the pressure reservoir.
i HoM the pump assembly in position when
lightening the pressure reservoir.
a 3. Undo the pressure reservoir (No. 5). Use a

universal fiiter wrench - e.g. Hazet 2171-2 -
Note
Wet the seal ring with brake fluid only. Never

for this purpose. use brake-cylinder paste. Absolute cleanli-
Important: Never loosen at the filler ness is essential. Use only lint-free cleaning
screw X, as the gas pressure will escape cloths.
abruptly in this case.

Printed in Germany - XXXV. ,995
39 Differential. transaxle system 928
2. Bleed the pressure reservoir and lock so- 3. Repeat the last process (fully charging
lenoid valve as follows: the pressure reservoir and then reducing
Open the bleeder valve on the lock solenoid the reservoir pressure to zero) approx.
valve. Push the electrical plug onto the f-2 times (brake fluid must be free from
pump wtih the ignition switched on. Pull off air bubbles).
the electrical plug and close the bleeder
valve as soon as the brake fluid emerges
wtthout air bubbles (use a collection bottle). 4. Bleed lock cylinder and pressure lines.
Now fully charge the pressure raservoir. For this purpose, the lock solenoid valve is
Push on the electrical plug. As soon as the pulsed with system tester 9289. The high
pump is heard to switch off, pull off the pressure present at the solenoid valve there-
electrical plug and reduce the pressure at by enters the pressure lines in pulses and
the bleeder valve of the lock solenoti valve reaches the lock cylinder via the non-return
to zem (slowly open the bleeder valve I use valve.
a collection bottle).
Important: The system is under a press-
Drain off brake fluid at the bleeder valve of
the lock cylinder until no more air bubbles
l
ure of up to 180 bar. Wear goggles and appear.
protective gloves.
Note 5. After completing the assembly and bleeding

work, correct the brake fluid level
;tr a filling and bleeding untt is not connected,
-with the pressure reservoir fully charged.
always check the level in the fluid reservoir
between bleeding processes and top up with
brake fluid if necessary.
039 - 260 PSD diagnosis/Troubleshooting

a
Printed in Gemmy - xxxv. 1996

WM Porsche 928 Factory Manual - Vol 3

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Workshop Manual

DR. ING. h. c. F. PORSCHE Aktiengesellschaft

@ 1977 Dr. Ing. h.c. F. Porsche Aktiengesellschaft

All rights resewed - Printed in Germany XX, 1986

WKD 481 621

Print No. W 42-608-126-l

General Technical Data Paae 0.1

Chassis Front Wheel Suspension 40

Printed in Germany - XX, 1997

Transmission I Gears, Valve Body

Disassembling and assembling secondaty pump ............... 38-l 55

Differential I Transaxle system

1 - Front converter casing 2 - Automatic transmission

Transmission Type installed in

A 28.02 928 S, Special option for Europe / rest of the

A 28.03 928 S, Special option (M 251) Europe / rest

A 28.04 928 S, USA series / '85 models for Japan

A 28.05 928 S, Special option Europe / '85 models

0 A 28.06 928 S, Special option (M 251) Europe / '85 models

A 28.07 928 S, USA series / '86 models for Japan

A 28.08 928 S, Special option Europe / '86 models

A 28.09 928 S, Special option (M 251) Europe / '86 models

A 28.11 928 S, Australia series, special option (M 299)

0 Printed in Germany-XX,1988 Technical Data 30 - 0101

4-speed automatic transmlsslon (‘87 models onward)

1 - Front converter casing 2 - Automatic transmission

Type Key-number Equipment Installed In model a

A28.12 - 928 S 4 USNJap. 87188

A28.14 - 928 S 4 R.d.W. 87188

A28.16 - 928 S 4 worldwide 89/90/91

A28.18 - 928 GTS worldwide 92/93

30 - 0102 Technical Data

72227012 01 722316 02.~ A28.01 7222702501 72231602...= A28.07

Technlcal Data 30 - 0102a

Transmlssion numbers (12 dlglts)

T Index for varlants Model year Serlal

* As of MY ‘92, the model letter is omitted.

30 - 0102b Technical Data a

General data A28.0 1/04/07/l 2 R8.02/03/05/06/08/09/11/14/16/18

Fully automatic 4-speed sun-an&planet transmis m

1st gear 368 3,87

Final drive Drive pinion without hypoid displacement

Final drive ratio 15 : 33 i = 2,200 14 : 33 i = 2,357 (A 28.02/05/08)

(Stall speed) A 28.01 = A 28.02/03/05/06/08/09/l 1 =

Capacity, rear up to MY ‘86 = approx. 2.7 I

Capacity, auto. Total capacity = approx. 8.01 (‘87 models onward,

* refer to Technical Information No. l/91 of 08.3.91

0 Technlcal Data 30 - 0103

TIGHTENING TORQUE FOR AUTOMATIC TRANSMISSION

Location Description Threads Material Torque

Primary pump Bolt M8 8.8 20 (14)

Plug Bolt MlOxl 10.9 14 (10)

Front cover Bolt M8 8.8 13 19)

Support flange Bolt M6 10.9 11 (8)

Plug Plug M 27 x 1.5 - 70 (51)

Catch plate on range Bolt M6 8.8 8 (6)

Leaf spring Bolt M6 8.8 8 (6)

Starter interlock 1 Bolt M6 8.8 8 (6)

Range selector lever 1 Bolt M6 8.8 8 (6)