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Workshop Manual
Volume II - Transmission
DR. ING. h. c. F. PORSCHE Aktiengesellschaft As webpage by http://www.9ss1.dk/porsche944
Page 1 of 369Porsche 944, 944 S and 944 S2 Transmissions - Workshop Manual volume II
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This Workshop Manual describes all of the important operations for which special instructions are required toassure proper completion. This manual is essential for shop foremen and mechanics, who need thisinformation to keep the vehicles in safe operating condition. The basic safety rules, of course, also apply torepairs on vehicles without exception.
Only those repair jobs deviating from those of vehicle type 924 are described in the 944 Workshop Manual.Refer to the 924 Workshop Manual for all other information.
The information is grouped according to repair numbers which are identical to the first two digits of the warrantyob codes.
The repair group index, list of contents and the register tabte are quick guides to find information in the manual.The layout drawings in this manual are numbered in the order of disassembling and, if necessary, also haveinformation on assembly or installation and application of special tools.
Descriptions of design and function can be found in the service training course reference material.
This Workshop Manual will be kept up to date with Technical Information Bulletins, which will be made part ofthe manual from time to time. We recommend that these bulletins be filed in the standard type folder providedfor this purpose.
WORKSHOP MANUAL 944
Page 2 of 369Porsche 944, 944 S and 944 S2 Transmissions - Workshop Manual volume II
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Printed in Germany
List of Repair Groups 944
General Technical Data Page 0.1
Repair Groups Group
Maintenance, Self-diagnosis 03
Engine Engine, Crankcase
Engine, Crankshaft, PistonsEngine, Cylinder Head and Valve DriveEngine, LubricationEngine, CoolingFuel Supply Air Flow Controlled Fuel InjectionExhaust System/Emission ControlsStarter, Power Supply, Cruise ControlIgnition SystemDME Diagnosis
10
131517192024262728
Transmission Clutch, ControlsTorque Converter Manual Transmission, Controis, Case
Manual Transmission, Gears, Shafts Autornatic Transmission, Controls, Case Automatic Transmission, Gears, Valve BodyDifferential, Transaxle System
303234
35373839
Chassis Front Wheel SuspensionRear Wheel Suspension, Axle ShaftWheels, Tires, Alignment Antiblock SystemBrakes, MechanicalBrakes, Hydraulics, Regulator, Booster Steering
40424445464748
Body Body-Front Section
Body-Center SectionBody-Rear SectionLidsDoorsHardtopBumpersGlasses, Window ControlExterior EquipmentInteriør EquipmentSeatsSeat Covers
50
5153555761636466687274
Page 3 of 369Porsche 944, 944 S and 944 S2 Transmissions - Workshop Manual volume II
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Airbag Diagnosis
Heating,Ventilation,Air Condition
Heater Ventilation Air Conditioner
808587
Electrics Instruments, Fuel Gauge, Alarm SystemRadio, Telephone
Windshield Wipers and Washer Exterior Lights, Lamps, SwitchesInteriør LightsWiring
9091
92949697
Printed in Germany - XXI, 1989
9 4 4
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0 Blank Page
944 Table of contents volume II
General data
Technical data (Type 016 J and 016 K)Technical data (Type 016Jand 016 K, Mod. 85/2 onward)Technical data (Type 016J/K and 083 D)Technical data(Type 083 F)Tightening torques (Type 016 J and 016 K)Technical data, clutch
Clutch, Control
Checking clutch play, adjusting clutch springChecking condition of clutch drive diskChecking release travel, bleeding hydraulic clutch systemClutch, removing and installing
Page
30 - 0130 - 0230 - 0330 - 0430 - 0530 - 07
30 - 130 - 230 - 330 - 5
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Clutch control, disassembling and assemblingChecking drive diskChecking pressure plateOverhauling slave cylinder
Automatic clutch, Torque convertor
Checking convertor (Type 087 M and 087 N)Draining convertor (Type 087 M and 087 N)Installing convertor (Type 087 M and 087 N)
Manual transmission, Control, Housing
Gearbox, removing and installing (Type 016 J and 016 K)Gearbox, removing and installing, Type 016 J and 016 K (Mod. 85/2 onward) Adjusting shiftChecking oil level, replacing transmission oilTransfer box, removing and installing (Type 016 J and 016 K)Transfer box, disassembling and assembling (Type 016 J and 016 K)Rear cover, disassembling and assembling (Type 016 J and 016 K)
End plate. disassembling and assembling (Type 016 J and 016 K)Transmission case, disassembling and assembling (Type 016 J and 016 K)
Manual transmission, Gears, Shafts
Input shaft, disassembling and assembling (Type 016 J and 016 K)Output shaft, disassembling and assembling (Type 016 J and 016 K)
30 - 1330 - 1630 - 1730 - 19
32 - 132 - 232 - 3
34 - 134 - 434 - 534 - 734 - 934 - 1534 - 27
34 - 3134 - 39
35 - 135 - 7
Table of contentsPrinted in Germany - XXII, 1989
1
volume II Table of contents 944
Automatic transmission
Technical data (Type 087 M and 087 N)
Page
37 - 01
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944 Table of contents volume II
Adjusting pinion and ring gear (Type 016 J and 016 K)Tightening torques (Type 087 M and 087 N)Checking oil level in rear final drive (Type 087 M and 087 N)Final drive, disassembling and assembling (Type 087 M and 087 N)Differential, disassembling and assembling (Type 087 M and 087 N)Limited slip differential (40%), disassembling and assembling Adjusting drive set (Type 087 M and 087 N)Central pipe, removing and instaIling (Type 087, M and 087 N)Central pipe, disassembling and assemblilig (Type 0,87 M and 087 N)Checking central pipe (Type 087 M and 087 N) Adjusting dampers (Type 087 M and 087 N)
Page
39 - 1139 - 10139 - 10339 - 10539 - 11939 - 122a39 - 12339 - 13539 - 14339 - 14539 - 146
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Table of contentsPrinted in Germany - XXII, 1989
3
30 G e n e r e l 9 4 4
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30 - 00 Blank Page
FIVE SPEED MANUAL TRANSMISSION 016 K
9 4 4 G e n e r e l 30
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Transmission Types Built Beginning With 1982 Model:
Type Code Installed in Cars for
016 K QM Standard
016 K 8 Q Optional (with limited slip differential)
Printed in Germany Technical Data (Type 016 K) 30 - 01
30 General 944
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5-speed manual transmission 016J and 016K (as from Model 85/2)
Type Identificationcode
Equipment Installed in Model year
016J 5Y 5-speed withoutlimited slip differential
Rest of the worldWorldwide
85/2...8888
016J 5Z 5-speed withlimited slip differential
Rest of the worldWorldwide
85/2...8888
016K 5S 5-speed without limited slip diff. USA/Japan 85/2...87
016K 7V 5-speed with limited slip diff. USA/Japan 85/2...87
016J ASG 5-speed without limited slip diff. Worldwide 89...91
016J ASH 5-speed with limited slip diff. Worldwide 89...91
30 - 02 Technical Data - (Type 016 J / K, as from Mod. 85/2)Printed in Germany - XVIV, 1991
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FIVE-SPEED MANUAL TRANSMISSION 083 D FOR 944 S ('87 MODELS ONWARD)
With the exception of a few modifications in its design and as regards repair the 083 D transmission is the same as the 016 R Turbo transmission.
The most important modifications are:
- no transmission-oil pump is available
- final drive ratio increased to 9 : 35
- transmission casing with machined recess for ring gear
- design distance "Ro" 58.15 mm
9 4 4 G e n e r e l 30
Type Code Installed in
083 D AGP Woldwide
083 D AGRWoldwide (withlimited-slipdifferential)
Page 13 of 369Porsche 944, 944 S and 944 S2 Transmissions - Workshop Manual volume II
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Printed in Germany - XIII, 1987 Technical Data(Type 083 D)
30 - 02a
Technical Data - Type 083 F
30 General 944
Type Code Equipment Installed in: Model Year
083F A0S
5-speed
without lock
944 S 2 worldwide
except Switzerland 1989/90/91
083F A0T5-speedwith lock
944 S 2 worldwideexcept Switzerland
1989/90/91
083F ASV* 5-speed without lock 944 S 2 Switzerland 1989/90/91
083F ASW* 5-speed with lock 944 S 2 Switzerland 1989/90/91
Page 14 of 369Porsche 944, 944 S and 944 S2 Transmissions - Workshop Manual volume II
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* with transmission enclosing and additional oil cooler.
Transmission 083 F is the same in design and repairing procedures as the 944 S transmission 083 D,except for a few deviations.
Most Important Deviations:
- Longer 5th gear 36 : 28 i = 0.778- Final drive ratio 8 : 31 i = 3.875
- Design distance "Ro" = 59.65 mm- Stronger differential
30 - 02b Technical Data - Type 083 FPrinted in Germany - XVIV, 1991
944 General Data 30
General Data 5 Speed Manual Transmission 083 F
016 J / 016K 083 D (AGP/AGR)
Ratios
1st gear 10 : 36 i = 3,6000 10 : 35 i = 3.500
2nd gear 16 : 34 i = 2,1250 17 : 35 i = 2.059
3nd gear 24 : 35 i = 1,4583 25 : 35 i = 1.400
4nd gear 28 : 30 i = 1,0714 29 : 30 i = 1.034
5nd gear 35 : 29
(37 : 27
i = 0,8286
i = 0,7297)
35 : 29 i = 0.829
Reverse gear 12 : 42 i = 3,5000 12 : 42 i = 3.500
Final drive Hypoid pinion/ring gear with 12 mm offset
Final drive ratio 9 : 35 i = 3.889
Power transmission Front-mounted engine and rear-mounted transmission connected via apipe to form a bolted drive unit. Front-mounted engine. clutch, rotationally
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USA values in parentheses
Rest of the world and USA vehicles have the same transmission ratio as from model 88.
elastic shaft (25 mm dia.) running on 4 bearings in connecting pipe to thetransmission, rear-mounted transmission bolted on final drive, double driveshafts to the rear wheels.
Filling capacity Approx. 2.0 liters hypoid transmission oil SAE 75 W 90 to API Class GL5 or MIL-L 2105 B, or SAE 80 to API Class GL 4 or MIL-L 2105 (refer to page 34 - 7)
Technical Data - Type 083 FPrinted in Germany - XXIV, 1991
30 - 03
Technical Data - Type 083 F
30 General 944
General Data 5 Speed Manual Transmission 083 F
Ratios
1st gear 10 : 35 = 3.500
2nd gear 17 : 35 = 2.059
3nd gear 25 : 35 = 1.400
4nd gear 29 : 30 = 1.043
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5nd gear 36 : 28 = 0.778
Reverse gear 12 : 42 = 3.500
Final Drive Hypoid pinion/ring gear with 12 mm offset
Final Drive ratio 8 : 31 = 3.875
Power transmission Front-mounted engine and rear-mounted transmission connected via apipe to form a bolted drive unit. Front-mounted engine, clutch, rotationallyelastic shaft (25 mm dia.) running on 4 bearings in connecting pipe to thetransmission, rear-mounted transmission bolted on final drive, doubledrive shafts to the rear wheels.
Filling capacity Approx. 2.0 liters hypoid transmission oil SAE 75 W 90 to API Class GL5or MIL-L 2105 B, or SAE 80 to API Class GL or MIL-L 2105 (refer to page 34 - 7).
30 - 04 Technical Data - Type 083 FPrinted in Germany - XVIV, 1991
Torque specifications for manual transmission
944 General Data 30
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* Screws are microencapsulated. Must only be used once.
Location Description Threads Material class Tightening torqueNm (ft.lb)
Oil filter plug in
transmission case
Oil drain plug intransmission case
Gear shift shaftcover to transmis-sion case
End shield to trans-mission case
Ball bearing to inputshaft
Cover to end shield
5th gear wheel topinion
Shift lock to endshield and transmis-sion housing
Shift travel stop toend shield
Plug
Plug
Hexagon headscrew
Hexagon headscrew
Hexagon headscrew*
Fillister headscrew
Hexagon headscrew*
Threadedbushing
Stop screw
M 24
M 24
M 6
M 8
M 10
M 8
M 10
M 18
M 14
-
-
8.8
8.8
8.8
8.8
8.8
-
8.8
24 (17)
24 (17)
8 (6)
24 (17)
70 (51)
24 (17)
70 (51)
30 (22)
30 (22)
Torque specifications (Typ 016 J/K)Printed in Germany - XVII, 1988
30 - 05
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30 General Data 944
Location Description Threads Material class Tightening torqueNm (ft.lb)
Reversing lever toend shield
Reverse gear bolt toend shield
Stub shaft to diffe-rential
Side transmissioncover to transmis-sion case
Ring gear to diffe-rential case
Back-up light switchto transmission case
Speedometer bushing to transmis-sion case
Crankshaft to flange
Cross-reces-sed fillister head screw
Hexagon headscrew withcollar
Screw
Hexagon headscrew
Hexagon headscrew
Switch
Speedometer bushing
Hexagonsocket screw
M 10
M 8
M 8
M 8
M 10
M 18
M 18
M 8
8.8
8.8
8.8
10.9
12.9
-
-
12.9
35 (25)
24 (17)
24 (17)
24 (17)
90 (66)
42 (42)
42 (30)
42 (30)
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30 - 06 Torque specifications (Typ 016 J/K)Printed in Germany - XVII, 1988
9 4 4 G e n e r a l 30
General Data Clutch
Design
Pressure plate
Clutch disc
Single plate, dry clutch with diaphragm springs,pull release version, located on engine,hydraulic operation
MFZ 225 contact pressure 6100 - 6800 N(1370 - 1530 lb)
225 GUD (with rubber torsion damper)
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Printed in Germany Technical Data 30 - 07
TlGHTENING TORQUE FOR CLUTCH, CENTRAL TUBE, TRANSMISSION SUSPENSION ANDSHIFT LINKAGE
30 G e n e r a l 9 4 4
Location Description Threads Material TorqueNm (ft lb)
CLUTCH
Guide sleeve on clutchhousing
Clutch and gear ringinstallation
Flywheel to crank-shaft
Clutch housing toengine
Guard and supportto clutch housing andcrankcase
Release lever shaftwith clutch housing
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
M7
M8
M 10
M 12
M 10
M6 x 35
M6
8.8
8
10.9
8.8
8.8
8.8
8
15 (11)
25 (18)
90 (65)
75 (54)
42 (30)
9.5 (7)
7.5 (6)
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Reference mark andspeed sensors toholder
Slave cylinder toclutch housing
Master cylinder to
firewall
Clutch tube to clutchhose or to master andslave cylinders
Drive shaft to trans-mission input shaft
Central tube flangeto clutch housing
Bolt
Bolt
Nut
Coupling
Clamp bolt
Bolt
M6
M8 x 28
M8
M 12
M 10 x 46
M 10 x 35
8.8
8.8
8
12.9
8.8
8 (6)
21 (15)
21 (15)
16 (11)
80 (58)
42 (30)
30 - 08 Technical Data Printed in Germany
9 4 4 G e n e r a l 30
Location Description Threads Material Torque inNm (kpm)
Central tube housingto transmission case
Bolt M 12 x 75
M 12 x 80
M 10 x 60
10.9
10.9
8.8
85 (8.5)
85 (8.5)
42 (4.2)
TRANSMISSION SUSPENSION (Double Point Suspension)
Transmission mountto body
Mount to bracket
Bolt
Bolt
M 10
M 8
8.8
8.8
46 (4.6)
25 (2.5)
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Bracket totransmission
Bolt M 8 10.9 25 (2.5)
TRANSMISSION SUSPENSION (Single Point Suspension)
Transmission carrier to body
Transmission mountto transmission carrier
Bracket to transmis-sion mount
Bracket to transm.
Bolt
Bolt
Bolt
Bolt
M 10
M 8
M 8
M 8
8.8
8.8
8
8
46 (4.6)
23 (2.3)
23 (2.3)
23 (2.3)
SHIFT
Joint rod totransmission case
Joint rod to inter-mediate shift lever
Shift rod
Shift lever plate tocentral tube
Intermediate shiftlever to shift shaft
Ball-ended bolt
Nut
Bolt
Bolt
Bolt
M 8
M 8
M 8
M 8 x 12
M 8
9 S Mn 28 K
8.8
9 S Mn 28 K
8.8
14 (1.4)
21 (2.1)
21 (2.1)
21 (2.1)
22.5 (2.25)
Printed in Germany - V, 1985 Technical Data 30 - 09
30 Clutch/Controls 9 4 4
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30 - 0 Blank Page
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* Values of distance A in parentheses apply to spring when removed.Reassemble servospring/guide rod with assembly wire (3 mm dia. split pin).
9 4 4 Clutch/Controls 30
CHECKING CLUTCH PLAY
Automatic hydraulic clutch
adjustment means that clutch playcannot be checked at the clutchpedal.
Nevertheless, the clutch cannotoperate correctly unless there is0.5 mm clearance between push rodand master-cylinder piston.
This play cannot be measured; it isabout 3 mm at the pedal pad andmust be determined by feel.
If necessary, correct play by
adjusting piston rod.
ADJUSTING CLUTCH SPRING
A spring which reduces the pedal
force is installed to assist theforce applied to the pedal. For this purpose, the spring must bepreloaded accordingly.
Measure distance A between outer edge of plate and bearing withclutch engaged (clutch pedal at endstop).
If necessary, correct by turning the hex nut.
- Distance A for green color-codedspring (no longer available asspare part) 60 mm (75 mm*)
- Distance A for blue color-codedspring (increased spring rate/inuse since February 1986)= 55 mm (68 mm*)
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Printed in Germany - XIII, 1987 Checking Clutch Play Adjusting Clutch Spring
30 - 1
CHECKING CLUTCH DRIVE PLATE FOR WEAR
Checking
Remove cap
Measure distance "A" witha suitable gage
30 Clutch/Controls 9 4 4
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Size newWear limit
18 mm34 mm
30 - 2 Checking Clutch Drive Plate Printed in Germany
If distance is less than 15 mm there can be no guarantee that clutch disengages fully.
BLEEDING CLUTCH
G e n e r a l I n f o r m a t i o n
The use of a pressure bleeder is recommended.
9 4 4 C l u t c h / C o n t r o l s 30
CHECKING RELEASE TRAVEL
1.
2.
Remove cap (see page 30 - 2).
Measure distance "B" with a
suitable measuring tool.
123B
Clutch slave cylinder Push rodRelease lever Release travelNominal value =15 to 18 mm
Possible Causes: -
---
air in hydraulic system
clutch master and/or slave cylinders defective (cups)no or insufficient clutch playlimited clutch pedal travel (e. g. bunched-up floor mats)
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1. Fill tank with brake fluid to upper edge.Remove restrictor sleeve. Connect bleeder.
N o t e
Never operate clutch pedal as long as slavecylinder is removed.
2. Switch on bleeder and open bleeder screw onclutch slave cylinder until escaping fluid iswithout air bubbles. Operate clutch pedalseveral times during this step.
3. If necessary because of residual air (releasetraver less than 15 mm), unscrew slave cylinder on clutch housing. Push rod against stop inslave cylinder and release again (bleeder switched off, brake fluid tank not filled toupper edge). This will force the residual air back into the clutch line or master cylinder/brake fluid tank.
Printed in Germany Checking Release Travel, Bleeding Clutch 30 - 3
30 C l u t c h / C o n t r o l s 9 4 4
4. Install slave cylinder again.Repeat bleeding procedures.
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30 - 4 Bleeding Clutch Printed in Germany
REMOVING AND INSTALLlNG CLUTCH
9 4 4 C l u t c h / C o n t r o l s 30
Note 3. Remove exhaust assembly. This requires
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When performing operations on the transaxlesystem that involve rotating or shifting thetransaxle tuebe, always wear leather glovesto avoid injuries.
R e m o v i n g
1. Disconnect ground wire at battery. Disconnectround wire connecting body with clutch housing.
2. Disconnect ground wire on clutch housing I.Unscrew socket head bolts and run referencemark sensor II and speed sensor III for DEEout of holder IV.Disconnect wire harness for starter at upper mounting point V.If necessary, remove air cleaner for this step.
unscrewing exhaust pipe on exhaust manifoldand suspension mounting bolts. If car has oxygencontrol, disconnect wires of oxygen sensor on plug.
Printed in Germany Removing and Installing Clutch 30 - 5
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30 C l u t c h / C o n t r o l s 9 4 4
4. Remove heat shield above catalytic converter.Remove splash guard. Run out rear exhaustpipe bracket together with bracket bolted on the
central tube.
5. Push back dust cover. Remove lockwire on clampbolt of selector linkage. Unscrew bolt.
6. Lift and fold down dust cover and sleeve on shiftlever. Remove shift lever knob retainer. Take off shift lever knob.
7. Remove circlip on shift lever. Pull off selector rod and washer on bolt of shift lever.
8. Remove insulator above shift lever console.Remove shift lever, but first mark location of console after removing the rear mounting bolt.
9. Press down on insulation sheet and push selector rod forward in cavity by about 300 mm(12 in.).
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30 - 6 Removing and Installing Clutch Printed in Germany
9 4 4 C l u t c h / C o n t r o l s 30
10. Unscrew two upper mounting bolts of clutch housing.
11. Take off end cap on central tubehousing. Push back protective tube for selector rod far enough, that it isoutside of the central tube housing.This is done by inserting a large screw-driver through assembly opening incentral tube housing and openingretainer on protective tube.
13. Detach joint shafts on transmission end,but do not let joint shafts hang downto final stop in joint (instead suspendfrom car with wire) to avoid damage.
14. Pull off wires on backup light switch. Also pull off plug on speedometer drive
of cars since 1985/2 models (see page34 - 4).
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12. Unscrew and remove clamping sleevebolts through assembly openings.Push clamping sleeve in direction of transmission.
Printed in Germany - V, 1985 Removing and Installing Clutch 30 - 7
30 C l u t c h / C o n t r o l s 9 4 4
I n i t i a l V e r s i o n
P r e s e n t M o d i f i e d V e r s i o n
15. Run in a workshop trolley jack fitted withSpecial Tool 9115 or an universal trans-mission jack underneath the transmission.Lift transmission slightly to removepressure on suspension.
16. Remove transmission suspension bolts.
19. Remove starter. Unscrew clutch linemounting clamp, Detach clutch slavecylinder on clutch housing (do notopen hydraulic system).
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17. Lower transmission with central tubeuntil central tube rests on the rear axle cross tube.
18. Remove transmission/central tube
flange bolts. Remove transmissiondownward.
20. Disconnect starter wire harness onclutch housing. Pull out release lever shaft mounting bolt with a 8 mmbolt. Unscrew the tour central tube/clutch housing mounting bolts.
30 - 8 Removing and Installing Clutch Printed in Germany
9 4 4 C l u t c h / C o n t r o l s 30
21. Pull back selector rod again, which had beenpushed forward for removal of the transmission,so that nothing will be damaged when movingthe central tube.
22. Move back central tube far enough until centraltube housing rests on transmission carrier. If central tube cannot be moved out of clutchhousing without applying force, hold enginetight with transport eye mounted oncamshaft housing with Special Tool VW 10-222.
24. Unscrew two lower mounting bolts on clutchhousing, after unscrewing engine mount nutsand pushing engine to the right
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In this case the engine has excessive inclinationat rear - check engine suspension.
N o t eMake sure brake lines are not damaged by thecentral tube.
23. Unscrew guard on clutch housing. Remove rightsupport, insofar as car is fitted with supports.
25. Move out guard and clutch housing with releaselever.
26. Disconnect clutch on flywheel.
Printed in Germany Removing and Installing Clutch 30 - 9
30 C l u t c h / C o n t r o l s 9 4 4
I n s t a l l i n g 4. Mount clutch housing and release lever together on engine/release bearing.This requires that the bolt glued on the flywheel
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1. Check flywheel, starter gear ring, pilot bearing inflywheel, crankshaft seal, release bearing, guidesleeve, release lever, pressure plate and clutchdisc for wear or damage.
2. Coat guide sleeve with multi-purpose MoS2grease.Give spline of drive shaft and area in pilot bearing/flywheel a light coat of MoS2. Lubricate releaselever (pivot, ball socket and needle bearings) withwhite solid lubricating pasta AOS 126 0006.
3. Install clutch. This requires that friction surfacesbe clean and without grease. Use short drive shaftof a 928 (or a shortened drive shaft from adamaged central tube) to center the clutch disc.Screw in bolts uniformly crosswise. Tighteningtorque = 25 Nm (18 ft Ib). Counterhold on hexa-gon bolt of front pulley.
for the reference mark sensor faces down(danger of damage).Insert cover. Mount clutch housing with thetwo lower bolts.
5. Move release lever until needle bearing and borein clutch housing align. Slide in release lever shaft positioned correctly so that machinedsurface faces mounting bolt against stop. If necessary, move release lever back and forth -but never use force!
6. Screw in mounting bolt for a correctly installedrelease lever shaft and lock with out.
7. Bolt clutch housing, cover and, if applicable,right support. Connect starter wire harness.Mount start and reference mark sensors as wellas ground wires on clutch housing and body.
30 - 10 Removing and Installing Clutch Printed in Germany
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9 4 4 C l u t c h / C o n t r o l s 30
N o t e
To avoid tension in engine, transmission and centraltube, when installing in car tighten central tube toclutch housing mounting bolts only after bolting theengine and transmission.
10. Install clutch slave cylinder. Mount clutch line.
8. Check that insulation sheet on central tube is stillpositioned correctly. Distance from flange insideto insulation should be 500 mm (20 in.).
9. Push central tube forward and bolt on clutchhousing. Guide central tube with drive shaft intoclutch housing and clutch disc carefully (danger of damage). Never apply force. Screw in mountingbolts and loosen again by about 1 turn. (Never tighten bolts fully, see note!)
11. Place selector rod protective tube in trans-mission case. Replace a selector rod protectivetube, if retainer is deformed excessively.
Install transmission.Push selector rod protective tube forward untilretainer engages in transmission case.Mount selector rod on intermediate shift lever.
12. Tighten mounting nuts insofar as enginemounted had been unscrewed.Then bolt central tube on clutch housing tospecified torque (bolts had only been screwedin finger tight. see point 9).
13. Repair any damage on splash guard caused byremoval of transmission or moving of centraltube. Install starter and exhaust assembly.
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Printed in Germany Removing and Installing Clutch 30 - 11
30 C l u t c h / C o n t r o l s 9 4 4
14. Mount shift lever so that inclination in neutral is85° (refer to mark).
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30 - 12 Removing and Installing Clutch Printed in Germany
DISASSEMBLlNG AND ASSEMBLlNG CLUTCH CONTROLS
9 4 4 C l u t c h / C o n t r o l s 30
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Printed in Germany Disassembling and Assembling Clutch Controls 30 - 13
30 C l u t c h / C o n t r o l s 9 4 4
No. Description Qty.
Note When:SpecialInstructionsRemoving Installing
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1
2
3
4
5
6
7
8
9
Bolt
Lockwasher
Slave cylinder
Bolt 6 x 35
Nut (locknut)
Cap
Release lever shaft
Clutch housing
Release lever
2
2
1
1
1
1
1
1
1
Do not operateclutch pedal after
removing cylinder (line connected)
Pull out with a8 mm bolt (stud)
Replace. if necessary
Tighten after pushing in releaselever shaftcorrectly
Push in againststop in correct
position - machinedsurface facesbolt 4
Mount clutchhousing andrelease lever together on engine/release bearingbefore installingrelease lever shaft
Lubricatebearing surfaceswith a whitesolid lubricatingpaste(AOS 126 0006)
Torque: 21 Nm(15ft lb)
Refer to point 8
Refer to point 8.Do not use force!
Move release lever back and forthslightly throughsight hole
30 - 14 Disassembling and Assembling Clutch Controls Printed in Germany
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9 4 4 C l u t c h / C o n t r o l s 30
No. Description Qty.
Note When:SpecialInstructionsRemoving Installing
10
11
12
Bolt
Guide sleeve
Needle bearing
3
1
2
Coat slidingsurfaces withmulti-purposegrease MoS2
Press in flush witha suitable mandrel.Lubricate withwhite solidlubricating paste(AOS 126 0006)
Torque: 9.5 Nm(7 ft lb)
Check for wear
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Printed in Germany Disassembling and Assembling Clutch Controls 30 - 15
CHECKING DRIVE PLATES
N o t e
Clutch liners cannot be replaced.
30 C l u t c h / C o n t r o l s 9 4 4
1. Inspect splines. Drive plate must slide easily on
input shaft in axial direction without radial play.
2. Check rivets and rubber torsion damper for cracks or damage. Replace drive plate when in doubt.
3. Inspect clutch liners. If clutch liners are covered withoil, burnt, damaged or worn at spots, install a newdrive plate.
4. Check liner thickness of drive plates.Drive plate with riveted liner:Relaxed thickness: 8.1 +- 0.3 mm.Relaxed wear limit: 6.3 mm for symmetrical wear.
5. Check drive plate with liner for lateral runout.Max. permissible lateral runout 0.6 mm measuredpprox. 2 to 3 mm from outside diameter.
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30 - 16 Checking Drive Plates Printed in Germany
This page is missing
9 4 4 C l u t c h / C o n t r o l s 30
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Blank Page 30 - 17
30 C l u t c h / C o n t r o l s 9 4 4
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This page is missing
30 - 18 Blank Page
OVERHAULING CLUTCH SLAVE CYLINDER
9 4 4 C l u t c h / C o n t r o l s 30
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Printed in Germany Overhauling Clutch Slave Cylinder 30 - 19
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30 C l u t c h / C o n t r o l s 9 4 4
No. Description Qty.
Note When:SpecialInstructionsRemoving Installing
1
2
3
4
5
6
7
8
9
10
Circlip
Push rod
Rubber cover
Retainer
Piston
Cup
Spring
Dust cap
Bleeder screw
Clutch slavecylinder
1
1
1
1
1
1
1
1
1
1
Replace. curvedsurface faces in.Make sure of perfect fit
Replace
Replace. applyvery thin coat of brake cylinder paste
Position correctly
Always cleanwith alcohol. applyvery thin coat of brake cylinder paste in cylinder bore
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30 - 20 Overhauling Clutch Slave Cylinder Printed in Germany
CHECKING TORQUE CONVERTER
9 4 4 T o r q u e C o n v e r t e r 32
1. Converter identification on lug:
K = USA/Japan
2. Check hub of converter for signs of scoring(arrow).
3. Check free movement of turbine with the turbine
N o t e :
The torque converter is a welded part and must bereplaced as a complete unit when damaged.
4. Check bearing sleeve visually for damage.measuring with an internat calipers if necessary.
Wear limit = max. 34.25 mm dia.Out-of-round = max. 0.03 mm
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shaft inserted.
Printed in Germany - I, 1982 Checking Torque Converter (Type 087 N)
32 - 1
DRAINING TORQUE CONVERTER
32 T o r q u e C o n v e r t e r 9 4 4
Drain the torque converter when ATF has abrasiveparticles or for a general overhaul.
1. Place converter at slight angle.
2. Connect a suitable hose (max. outside dia. 8 mmand small as possible inside diameter) on a plasticsuction bottle (2 liter /2 US qt capacity).
4. . Release the bottle so that the vacuum effect willdraw in the ATF.
5. Unserew the cap slightly as soon as the ATFruns to avoid pressure in the bottle.
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N o t e :
Cut angle or notch end of hose before inserting, sothat ATF can flow into hose.
3. Squeeze plastic bottle slightly and insert free end
of hose into converter hub until it touehes bottom.
32 - 2 Checking Torque Converter (Type 087 N)
Printed in Germany
INSTALLING TORQUE CONVERTER
9 4 4 T o r q u e C o n v e r t e r 32
1. Make sure pump shaft is inserted fully in pumpspline.
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CORRECT WRONG
N o t e :
The pump shaft has a tapered spline to make iteasier to engage the drive dog in the converter andoil pump.
2. Place converter on one-way clutch support care-fully; not tilting the converter.
3. Engage converter in splines by turning back andforth slightly.
Printed in Germany - I, 1982 Checking Torque Converter (Type 087 N)
32 - 3
34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
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www.9ss1.dk/porsche944
34 - 0 Blank Page
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REMOVING AND INSTALLlNG TRANSMISSION (TYPE 016 K)
9 4 4 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 34
R e m o v i n g
1. Remove catalytic converter together with muffler.
4. Remove circlip on shift lever.
2. Push back dust cover on selector rod, removelocking wire on bolt and unscrew bolt.
3. Remove holding clamp for shift lever knob andtake off knob.
5. Turn shift lever 180°. Push down on insulationsheet and push selector rod forward in tunnelcavity by about 300 mm (12 in.).
6. Remove end cap on central tube housing andpush back selector rod far enough, that it isoutside of the central tube housing.
This requires pressing in the retainer on theprotective tube with a large screwdriver appliedthrough opening in central tube housing.
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Printed in Germany Removing and Installing Transmission(Type 016 K)
34 - 1
34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
9. Pull off wires on backup light switch.
7. Unscrew clamping sleeve bolts through openingsand push clamping sleeve in direction of transmission.
8. Detach axle shafts on transmission end andsuspend from car on wire in horizontal position.
I n s t a l l i n g
10. Place universal transmission jack underneaththe transmission and secure retaining strap.
11. Remove transmission/central tube housingounting bolts.
12. Remove bolts on transmission suspension(rubber/metal mounts).
13. Lower transmission with central tube untilcentral tube rests on rear axle cross tube.Remove transmission from below.
1. Replace a selector rod protective tube if retainer is deformed excessively.
2. Place selector rod protective tube in transmission
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case. Tighten and bolt transmission. Tighten allmounting bolts to specified torque (see page30 - 08).
3. Push selector rod protective tube forward untilretainer engages in transmission case.
34 - 2 Removing and Installing Transmission (Type 016 K) Printed in Germany
9 4 4 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 34
4. Mount selector rod on intermediate lever andlock with steel wire.
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Printed in Germany Removing and Installing Transmission(Type 016 J and 016 K)
34 - 3
REMOVING AND INSTALLlNG TYPE 016 J AND 016 K TRANSMISSION(SINCE 1985/2 MODELS)
R e m o v i n g
34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
1. Remove final muffler.
2. Unscrew joint shafts on transmission endand suspend from car horizontally.
3. Pull off wires for backup light switch.
5. Push back dust cover on shift rod,
remove lock wire on bolt and unscrew bolt.
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4. Pull off plug on speedometer drive. 6. Press leather cover for shift knob outof center console carefully and pushup.
34 - 4 Removing and Installing Type 016 J and 016 KTransmission (Since 1985/2 Models)
V, 1985 - Printed in Germany
9 4 4 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 34
7. Remove mounting clamp for shift lever knob and take off knob,
10. Unscrew clamping sleeve screws throughassembly openings and push clampingsleeve toward transmission.
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8. Remove circlip on shift lever.
9. Turn shift lever 1800. Press down oninsulation sheet and push shift rodforward into produced cavity byabout 300 mm.
11. Push back protective tube through largeopening in case far enough, that it isoutside of the central pipe housing.Press in retainer with a large screwdriver for this purpose.
12. Hold transmission and central pipe ininstalled position, placing proper sizewooden block between cross tube andcentral pipe for this purpose.
13. Place universal transmission jack under-neath the transmission and attach strap.
Printed in Germany - V, 1985 Removing and Installing Transmission- Type 016 J and 016 K (Since 1985/2 Models)
34 - 4 a
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34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
I n s t a l l i n g
14. Remove transmission suspensionmounting bolts.
15. Remove transmission/central pipehousing mounting bolts.
16. Pull back transmission and run outdownward carefully.
1. Install transmission with universaltransmission jack.
2. Replace the shift rod protective tubewhen retainers are deformed excessively.
3. Place shift rod protective tube in trans-mission case. Run in transmission andbolt. Tighten all mounting bolts tospecified torque (see page 30 - 08/09).
4. Push shift rod protective tube forwarduntil retainer engages in transmissioncase.
5. Mount shift rod on intermediate lever and lock clamping bolt with steel wire.
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34 - 4 b Removing and Installing Transmission- Type 016 J and 016 K (Since 1985/2 Models)
Printed in Germany
9 4 4 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 34
ADJUSTlNG SHIFT LINKAGE
1. Adjust shift lever to an inclination of 85° by
moving the shift lever console. Shift lever shouldbe in neutral for this adjustment.
2. Shift lever in neutral. In this position a spring willhold the lateral selector shaft I in the center shiftplane (3rd and 4th gear). When shift was adjustedcorrectly, shift lever will not have lateral inclination. Adjustments are made on intermediate shift lever for joint rod.
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Printed in Germany Adjusting Shift Linkage 34 - 5
www.9ss1.dk/porsche944
34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
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34 - 6 Blank Page
CHECKING OIL LEVEL - REPLACING MANUAL TRANSMISSION OIL
9 4 4 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 34
Capacity: Approx. 2 l hypoid transmission oilSAE 75 W 90 to APl Class GL or MIL-L 2105B, or SAE 80 to API Class GL 4 or MIL-L 2105.
1. Clean outside of filler and drain plugs,and unscrew.
Note
The fluid level in the transmission housings
used in production is approx. 6 to 8 mmbelow the filler neck when 2 liters of trans-mission oil have been filled in.
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1 - Drain plug2 - Filler plug
2. Drain transmission oil of a car parkedon level ground or floor and transmis-sion having operating temperature.
3. Clean filler and drain plugs, and torqueto 24 Nm.
4. Pour in transmission oil with car parkedon level surface.
Printed in Germany - XXIV, 1991 Checking Oil Level - Replacing Transmission Oil 34 - 7
34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
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34 - 8 Blank Page
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TOOLS
9 4 4 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 34
No. Description Special Tool Remarks
1
2
Assembly stand
Assembly sleeve
VW 540
9178
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Printed in Germany Removing and Installing Gear Carrier (Type 016 K) 34 - 9
34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
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34 - 10 Removing and Installing Gear Carrier (Type 016 K) Printed in Germany
9 4 4 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 34
No. Description Qty.
Note When:SpecialInstructionsRemoving Installing
1 Threaded sleeve 1 Torque: 30 Nm(22 ft lb)
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2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Gasket
Spring
Sleeve
Bolt
Washer
Cover
Gasket
Selector shaftassembly
Dowel sleeve
Bolt
Gear carrier assembly
Bolt
Flange shaft
Bolt with washer
Cover
Differential
1
1
1
3
3
1
1
1
2
12
1
2
2
9
1
1 Remove trans-mission beforeremoving
Replace
Coat sealingsurface withoriginal VW D 3sealing compound
Position correctly -magnet facesdown
Light oil coat for tapered roller bearings andpinion teeth
Torque: 6 to 10 Nm(4 to 7 ft lb)
Torque: 24 Nm
(17 ft lb)
Torque: 25 Nm(18 ft lb)
Torque: 25 Nm(18 ft lb)
Printed in Germany Removing and Installing Gear Carrier (Type 016 K) 34 - 11
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34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
No. Description Qty.
Note When:SpecialInstructionsRemoving Installing
18 Transmission case 1 If transmission casehas to be replacedand deviation"r" is not on ringgear, check locationof drive pinionbefore removinggear carrier (actual distance)
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34 - 12 Removing and Installing Gear Carrier (Type 016 K) Printed in Germany
REMOVING AND INSTALLING GEAR CARRIER
9 4 4 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 34
R e m o v i n g
N o t e
The differential need not be removed for jobs on thegear carrier.
If the transmission case or tapered roller bearing for the drive pinion has to be replaced and deviation "r"is not given on the ring gear, measure actual locationof drive pinion befare removing the gear carrier.
1. Clamp transmission in assembly stand withSpecial Tool VW 540 and drain oil.
2. Remove threaded sleeve and locking parts for reverse gear lock.
3. Unscrew selector lever bolts and remove complete
I n s t a l l i n g
N o t e
It is recommended to install input shaft seal after installation of gear set (danger of damaging).
6. Unscrew gear carrier bolts and pull out gear
carrier with set of gears.
1. Give gear carrier/transmission case sealing surfacea thin coat of original VW D 3 sealing compound.Slide Special Tool 9178 on spline of input shaftand install gear carrier with set of gears intransmission case.
2. Drive in dowel sleeves and tighten mountingbolts to specified torque.
3. Check by shifting through all gears with SpecialTool 9155.
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selector shaft (do not disassembly).
4. Drive back dowel sleeves on gear carrier.
5. Slide Special Tool 9178 on spline of input shaft.
Printed in Germany Removing and Installing Gear Carrier (Type 016 K) 34 - 13
34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
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34 - 14 Blank Page
9 4 4 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 34
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Printed in Germany Disassembling and Assembling Gear Carrier (Type 016 K) 34 - 15
34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
No. Description Qty.
Note When:SpecialInstructionsRemoving Installing
1 End cover 1 Insert a large Replace
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2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Bolt 10 x 22 *
Washer
Bolt 8 x 45
Washer
Ball bearing inner race
Rear cover
Gasket
Ball bearing inner
race
Clutch body for 5th gear
Synchromesh ring
Dowel sleeve
Circlip
5th gear withsliding sleeve and
synchronizer
5th gear selector fork
Needle bearing
Stop bolt
Seal
1
1
7
7
1
1
1
1
1
1
1
1
1
1
1
2
2
screwdriver intocenter of rubber cover and pry out
Drive off with aplastic hammer
Pull off with a
two-arm puller
Replace
Heat to about
120 °C (250 °F)and drive on
Check for wear
Slide on slidingsleeve with short
collar facinggear
Only availablewith selector rodfor 5th gear
Install with gear lube
0.2 mm thick,
replace
Torque: 70 Nm(51 ft lb)
Torque: 25 Nm(18 ft lb)
Torque: 30 Nm(22 ft lb)
34 - 16 Disassembling and Assembling Gear Carrier (Type 016 K) Printed in Germany - XVII, 1988
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* Screws are microencapsulated. Must only be used once.
9 4 4 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 34
No. Description Qty.
Note When:SpecialInstructionsRemoving Installing
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Bolt 10 x 22 *
Washer
5th gear
Adjusting screw
Dowel sleeve
Dowel sleeve
Selector rod for 3rdand 4th gear
Small lock pin
Bolt for operatinglever
Operating lever
Input shaft
Selector fork for 3rd and 4th gear
Selector rod andselector fork for 1st
and 2nd gear
Drive pinion
Dowel sleeve
Gear carrier
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
Pull off with atwo-arm puller
Note thickness
Do not loose smalllock pin
Heat to about120 °C (250 °F)and install
If necessary,determine newthickness
Insert in selector rod with a liniegrease
Adjust operatinglever and torquebolt to 35 Nm(25 h tb)
Adjust beforeinstalling shafts
Press roller bearinginner race off of input shaft beforeinstalling
Determine new shimthickness whenreplacing
Torque: 70 Nm(51 ft lb)
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Printed in Germany - XVII, 1988 Disassembling and Assembling Gear Carrier (Type 016 K) 34 - 17
DISASSEMBLING AND ASSEMBLING GEAR CARRIER
34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
D i s a s s e m b l i n g
1. Remove end cover by puncturing center of rubber with a large screwdriver and prying off cover.
2. Clamp input shaft in a vise and unscrew inputshaft bolt. Fit vise with soft jaws!
4. Drive off rear cover with a plastic hammer andremove 1st inner race/ball bearing (A).
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3. Clamp gear carrier in vise and unscrew rear cover mounting bolts.
34 - 18 Disassembling and Assembling Gear Carrier (Type 016 K) Printed in Germany
9 4 4 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 34
6. Remove 5th gear synchromesh ring.
5. Pull off clutch body and 2nd inner race/ballbearing.
A - Two-arm puller (standard),e. g. Kukko 20/10
8. Remove circlip for synchronizer.
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7. Drive out 5th gear selector fork dowel sleeve.Hold with a hammer so that selector rod borein end bracket is not widened.
9. Remove 5th gear with sliding sleeve andsynchronizer, needle bearing and 5thgear selector fork.Selector rod remains in gear carrier!
Printed in Germany Disassembling and Assembling Gear Carrier (Type 016 K) 34 - 19
34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
10. Unscrew stop bolts for selector rods.
11. Clamp 4th gear/drive pinion in a vise andunscrew bolt for drive pinion.Make sure vise is fitted with soft jaws!
13. Remove shim for 5th gear.
14. Clamp gear carrier with shafts forward in vise.
A - Two-arm puller (standard)e. g. Kukko 20/10, if necessary grind off claws slightly or pry away gear slightlywith two tire irons.
15. Drive out dowel sleeve for dog on 1 st and 2ndgear selector rod, while holding with a hammer.Turn dog to face up.
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12. Pull off 5th gear.
16. Drive out dowel sleeve for 3rd and 4th gear selector fork, while holding with a hammer.
34 - 20 Disassembling and Assembling Gear Carrier (Type 016 K) Printed in Germany
9 4 4 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 34
20. Pull drive pinion forward far enough so thatselector rod and selector fork for 1st and2nd gears can be removed.
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N o t e: For transmissions with reverse gear syn-chronization disconnect spring clamp for reversegear on pinion shaft end and turn aside.
17. Pull out selector rod for 3rd and 4th gears(selector fork remains in sliding sleeve).Do not loose small lock pin!
18. Unscrew bolt for operating lever.
19. Pull drive pinion and input shaft forwardslightly. Remove input shaft with 3rd and4th gear selector fork.
21. Swing out drive pinion.
A s s e m b l i n g
1. Position lock pin in bore correctly.
2. Insert springs and sleeves for gear interlock(1st through 4th gears).
Printed in Germany - I, 1982 Disassembling and Assembling Gear Carrier (Type 016 K) 34 - 21
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34 M a n u a l T r a n s m i s s i o n / C o n t r o l s , C a s e 9 4 4
3. Adjust operating lever (see page 34 - 35).
4. Swing in drive pinjon, eng
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