Disassembling And Assembling Transmission Case Cover (Transmission G 86): Tools

Fig 1: Identifying Special Tools - Disassembling And Assembling Transmission Case Cover

Courtesy of PORSCHE OF NORTH AMERICA, INC.

SPECIAL TOOLS - DISASSEMBLING AND ASSEMBLING TRANSMISSION CASE COVER

No.	Designation	Special tool	Explanation
1(1)	Striking tool	VW 771
2(1)	Threaded piece	VW 771/15
3(1)	Pressure piece	9247/1
4(1)	Pressure piece	VW 295 a
5(1)	Pressure piece	3005
6(1)	Pull-in tool and extractor	P 254
7(1)	Threaded adapter (M10/M8)	-	Standard (e.g. Messrs. Kukko 18 - 008 A)
(1) For explanation see Fig 1

Fig 2: Exploded View Of Case Cover (Transmission G 86) Components

Courtesy of PORSCHE OF NORTH AMERICA, INC.

CASE COVER (TRANSMISSION G 86)

No.	Designation	Qty.	Removal	Installation
1(1)	Oil collecting vessel	1		Push in until the lock engages in the transmission case cover hole. The collecting vessel must face upwards.
2(1)	Snap ring	1
3(1)	Washer	1
4(1)	Reverse idler gear	1
5(1)	Needle roller bearing	2
6(1)	Thrust washer	1
7(1)	Retaining sleeve	1	Force out with a suitable internal puller and special tool VW 771	Do not reinstall (required only during manufacture in Production)
8(1)	Tapered roller bearing outer race	1	Remove with the special tools VW 771, VW 771/15 and standard threaded adapter	Press in with the special tool 3005 and a suitable plunger (e.g. special tool VW 407)
9(1)	Adjusting shim "S4"	X	Note the thickness for refitting	Measure again if necessary (2)
10(1)	Pressure plate	1
11(1)	Rubber disc	1	If necessary, drill a hole in the disc and pull out with a sheetmetal screw	Replace if necessary
12(1)	Needle roller bearing	1	Remove with the special tools VW 771, VW 771/15 and a suitable internal puller (e.g. Kukko 21/4, 22 - 28 mm). Destroy the plastic sleeve No. 13 before fitting the puller.	Always replace. Press in the correct position using the special tool VW 295 a and a suitable tubular piece (e.g. special tool VW 420). The large collar of the special tool VW 295 a faces the needle roller bearing
13(1)	Plastic sleeve	1	Is destroyed during removal	Always replace
14(1)	Bushing	1	Remove with the special tools VW 771, VW 771/15 and a suitable internal puller (e.g. Kukko 21/4, 23.5 - 30 mm)	Press in with the special tools 9247/1 and P 254
15(1)	Shaft seal	1	Lever out	Fill the chamber between the dust lip and sealing lip with multipurpose grease and drive in with a suitable tubular piece (e.g. special tool VW 423)
16(1)	Torx screw	1	Must be removed only if the reverse idler shaft is replaced	Tightening torque 35 Nm (26 ft.lb)
17(1)	Transmission case cover	1		If the cover is replaced, remeasure the adjusting shim "S4".(2) Seal with Loctite 573.
(1) For explanation see Fig 2 . (2) For adjustment, see ADJUSTMENT OVERVIEW (TRANSMISSION G 86) and DETERMINING "S4" AGAIN (TRANSMISSION G 86) .