Porsche training p30a drivetrain repair sports car

Training ObjectiveTraining objective After completing this training course, you should be able to carry out repairs to a transmission on your own, including all checks and adjustments..

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AfterSales Training

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Student Name:

Training Center Location:

Instructor Name:

Date: _

Important Notice: Some of the contents of this AfterSales Training brochure was originally written by Porsche AG for its

rest-of-world English speaking market The electronic text and graphic files were then imported by Porsche Cars N.A, Inc and edited for content Some equipment and technical data listed in this publication may not be applicable for our market Specifications are subject to change without notice.

We have attempted to render the text within this publication to American English as best as we could We reserve the right to make changes without notice

© 2010 Porsche Cars North America, Inc All Rights Reserved Reproduction or translation in whole or in part is not permitted without written authorization from publisher AfterSales Training Publications

Dr Ing h.c F Porsche AG is the owner of numerous trademarks, both registered and unregistered, including without limitation the Porsche Crest®, Porsche®, Boxster®, Carrera®, Cayenne®, Cayman™, Panamera®, Tiptronic®, VarioCam®, PCM®, 911®, 4S®, FOUR, UNCOMPROMISED SM and the model numbers and distinctive shapes of Porsche's automobiles such as, the federally registered 911 and Boxster automobiles The third party trademarks contained herein are the properties of their

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Description Section

Transmission Type Designations 1

911 Carrera (997) 6-Speed Transmission 2

Notes & Conversion Charts 3

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911, Boxster and Cayman Transmission Type Designations Since Model Year 1989

Model Transmission Technical Installed In

G50.01 5-Speed M/T 911 Carrera - USA, Australia, JapanG50.02 5-Speed M/T 911 Carrera - Switzerland

G50.50 5-Speed M/T 911 Turbo - World-WideG64.00 5-Speed M/T 911 Carrera (964) - RoW, USA/CanadaG64.01 5-Speed M/T 911 Carrera 4 (964) - Switzerland

1990 A50.01 4-Speed A/T 911 Carrera 2 (964) - RoW, USA/Canada

G50.03 5-Speed M/T 911 Carrera 2 (964) - RoW, USA/CanadaG50.04 5-Speed M/T 911 Carrera 2 (964) - SwitzerlandG64.00 5-Speed M/T 911 Carrera 4 (964) - RoW, USA/CanadaG64.01 5-Speed M/T 911 Carrera 4 (964) - Switzerland

1991 A50.01 4-Speed A/T 911 Carrera 2 (964) - RoW, USA/Canada

G50.03 5-Speed M/T 911 Carrera 2 (964) - RoW, USA/CanadaG50.04 5-Speed M/T 911 Carrera 2 (964) - SwitzerlandG50.52 5-Speed M/T 911 Turbo (964) - World-WideG64.00 5-Speed M/T 911 Carrera 4 (964) - RoW, USA/CanadaG64.01 5-Speed M/T 911 Carrera 4 (964) - Switzerland

1992 A50.02 4-Speed A/T 911 Carrera 2 (964) - RoW

A50.03 4-Speed A/T 911 Carrera 2 (964) - USA/CanadaG50.03 5-Speed M/T 911 Carrera 2 (964) - RoW

G50.04 5-Speed M/T 911 Carrera 2 (964) - SwitzerlandG50.05 5-Speed M/T 911 Carrera 2 (964) - USA/CanadaG50.10 5-Speed M/T 911 Carrera 2 RS (964) - RoWG50.52 5-Speed M/T 911 Turbo (964) - World-WideG64.00 5-Speed M/T 911 Carrera 4 (964) - RoW, USA/Canada

Transmission Number Identification

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A50.03 4-Speed A/T 911 Carrera 2 (964) - USA/Canada, TaiwanG50.03 5-Speed M/T 911 Carrera 2 (964) - RoW

G50.04 5-Speed M/T 911 Carrera 2 (964) - Switzerland/TaiwanG50.05 5-Speed M/T 911 Carrera 2 (964) - USA/CanadaG50.10 5-Speed M/T 911 Carrera 2 RS (964) - RoWG64.00 5-Speed M/T 911 Carrera 4 (964) - RoW, USAG64.01 5-Speed M/T 911 Carrera 4 (964) - SwitzerlandG64.02 5-Speed M/T 911 Carrera 4 (964) - Taiwan

A50.03 4-Speed A/T 911 Carrera 2 (964) - USA/Canada, TaiwanG50.03 5-Speed M/T 911 Carrera 2 (964) - RoW

G50.04 5-Speed M/T 911 Carrera 2 (964) - Switzerland/TaiwanG50.05 5-Speed M/T 911 Carrera 2 (964) - USA/CanadaG50.10 5-Speed M/T 911 Carrera 2 RS (964) - RoWG50.52 5-Speed M/T 911 Turbo 3.6 (964) - World-WideG64.00 5-Speed M/T 911 Carrera 4 (964) - RoW, USAG64.01 5-Speed M/T 911 Carrera 4 (964) - SwitzerlandG64.02 5-Speed M/T 911 Carrera 4 (964) - Taiwan

A50.05 4-Speed A/T 911 Carrera 2 (993) - USA/Canada, TaiwanG50.20 6-Speed M/T 911 Carrera (993) - USA/Canada

G50.21 6-Speed M/T 911 Carrera (993) - RoW

A50.05 4-Speed A/T 911 Carrera 2 (993) - USA/Canada, TaiwanG50.20 6-Speed M/T 911 Carrera 2 (993) - USA/Canada

G50.21 6-Speed M/T 911 Carrera 2 (993) - RoWG64.20 6-Speed M/T 911 Carrera 4 (993) - USA/CanadaG64.21 6-Speed M/T 911 Carrera 4 (993) - RoW

G64.51 6-Speed M/T 911 Turbo (993) - World-Wide

A50.05 4-Speed A/T 911 Carrera 2 (993) - USA/Canada, TaiwanG50.20 6-Speed M/T 911 Carrera 2 (993) - RoW, USA/CanadaG64.20 6-Speed M/T 911 Carrera 4 (993) - RoW, USA/CanadaG64.51 6-Speed M/T 911 Turbo (993) - World-Wide

A86.00 5-Speed A/T Boxster (986)G86.00 5-Speed M/T Boxster (986)

A50.05 4-Speed A/T 911 Carrera 2 (993) - USA/Canada, TaiwanG50.20 6-Speed M/T 911 Carrera 2 (993) - RoW, USA/CanadaG64.20 6-Speed M/T 911 Carrera 4/4S (993) - RoW, USA/CanadaG64.42 6-Speed M/T 911 Turbo (993) - Taiwan

G64.51 6-Speed M/T 911 Turbo (993) - RoW, USA/CanadaA86.00 5-Speed A/T Boxster (986)

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G86.00 5-Speed M/T Boxster (986)A96.00 5-Speed A/T 911 Carrera 2 (996) - RoW, USA/CanadaA96.30 5-Speed A/T 911 Carrera 4 (996) - RoW, USA/CanadaG96.00 6-Speed M/T 911 Carrera 2 (996) - RoW, USA/CanadaG96.30 6-Speed M/T 911 Carrera 4 (996) - RoW, USA/Canada

A86.20 5-Speed A/T Boxster S (986)G86.01 5-Speed M/T Boxster (986)G86.20 6-Speed M/T Boxster S (986)A96.00 5-Speed A/T 911 Carrera 2 (996) - RoW, USA/CanadaA96.30 5-Speed A/T 911 Carrera 4 (996) - RoW, USA/CanadaG96.00 6-Speed M/T 911 Carrera 2 (996) - RoW, USA/CanadaG96.30 6-Speed M/T 911 Carrera 4 (996) - RoW, USA/CanadaG96.90 6-Speed M/T 911 GT3 (996) - RoW

A86.20 5-Speed A/T Boxster S (986)G86.01 5-Speed M/T Boxster (986)G86.20 6-Speed M/T Boxster S (986)A96.00 5-Speed A/T 911 Carrera 2 (996) - RoW, USA/CanadaA96.30 5-Speed A/T 911 Carrera 4 (996) - RoW, USA/CanadaG96.00 6-Speed M/T 911 Carrera 2 (996) - RoW, USA/CanadaG96.30 6-Speed M/T 911 Carrera 4 (996) - RoW, USA/CanadaG96.50 6-Speed M/T 911 Turbo (996) - World-Wide

A96.50 5-Speed A/T 911 Turbo (996) - World-WideG96.88 6-Speed M/T 911 GT2 (996) - World-WideG96.90 6-Speed M/T 911 GT3 (996) - RoW

A96.50 5-Speed A/T 911 Turbo (996) - World-WideG96.88 6-Speed M/T 911 GT2 (996) - World-Wide

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A96.50 5-Speed A/T 911 Turbo (996) - World-WideG96.88 6-Speed M/T 911 GT2 (996) - World-WideG96.96 6-Speed M/T 911 GT3 (996) - USA/Canada

A87.20 5-Speed A/T Boxster S (987)G87.01 5-Speed M/T Boxster (987)G87.20 6-Speed M/T Boxster S (987)A96.10 5-Speed A/T 911 Carrera 2 (996) - RoW, USA/CanadaA96.35 5-Speed A/T 911 Carrera 4 (996) - RoW, USA/CanadaG96.01 6-Speed M/T 911 Carrera 2 (996) - RoW, USA/CanadaG96.31 6-Speed M/T 911 Carrera 4 (996) - RoW, USA/CanadaA97.01 5-Speed A/T 911 Carrera/S (997) - RoW, USA/CanadaG97.01 6-Speed M/T 911 Carrera/S (997) - RoW, USA/CanadaG96.50 6-Speed M/T 911 Turbo (996) - World-Wide

A87.20 5-Speed A/T Boxster S (987)G87.01 5-Speed M/T Boxster (987)G87.20 6-Speed M/T Boxster S (987)A87.21 5-Speed A/T Cayman S (987)G87.21 6-Speed M/T Cayman S (987)A97.01 5-Speed A/T 911 Carrera 2/S (997) - RoW, USA/CanadaG97.01 6-Speed M/T 911 Carrera 2/S (997) - RoW, USA/CanadaA97.31 5-Speed A/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.31 6-Speed M/T 911 Carrera 4/S (997) - RoW, USA/Canada

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A87.21 5-Speed A/T Boxster S (987)G87.01 5-Speed M/T Boxster (987)G87.21 6-Speed M/T Boxster S (987)A87.02 5-Speed A/T Cayman (987)A87.21 5-Speed A/T Cayman S (987)G87.01 6-Speed M/T Cayman (987)G87.21 6-Speed M/T Cayman S (987)A97.01 5-Speed A/T 911 Carrera 2/S (997) - RoW, USA/CanadaG97.01 6-Speed M/T 911 Carrera 2/S (997) - RoW, USA/CanadaA97.31 5-Speed A/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.31 6-Speed M/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.50 6-Speed M/T 911 Turbo (997) - World-Wide

A97.50 5-Speed A/T 911 Turbo (997) - World-WideG97.90 6-Speed M/T 911 GT3 (997) - USA/Canada

A87.21 5-Speed A/T Boxster S (987)G87.01 5-Speed M/T Boxster (987)G87.21 6-Speed M/T Boxster S (987)A87.02 5-Speed A/T Cayman (987)A87.21 5-Speed A/T Cayman S (987)G87.01 6-Speed M/T Cayman (987)G87.21 6-Speed M/T Cayman S (987)A97.01 5-Speed A/T 911 Carrera 2/S (997) - RoW, USA/CanadaG97.01 6-Speed M/T 911 Carrera 2/S (997) - RoW, USA/CanadaA97.31 5-Speed A/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.31 6-Speed M/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.50 6-Speed M/T 911 Turbo (997) - World-Wide

CG2.20 7-Speed PDK Boxster S (987)G87.10 6-Speed M/T Boxster (987)G87.40 6-Speed M/T Boxster S (987)CG2.00 7-Speed PDK Cayman (987)CG2.20 7-Speed PDK Cayman S (987)G87.10 6-Speed M/T Cayman (987)G87.40 6-Speed M/T Cayman S (987)CG1.00 7-Speed PDK 911 Carrera 2/S (997) - RoW, USA/CanadaG97.05 6-Speed M/T 911 Carrera 2/S (997) - RoW, USA/CanadaCG1.30 7-Speed PDK 911 Carrera 4/S (997) - RoW, USA/CanadaG97.35 6-Speed M/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.50 6-Speed M/T 911 Turbo (997) - World-Wide

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CG2.20 7-Speed PDK Boxster S (987)G87.10 6-Speed M/T Boxster (987)G87.40 6-Speed M/T Boxster S (987)CG2.00 7-Speed PDK Cayman (987)CG2.20 7-Speed PDK Cayman S (987)G87.10 6-Speed M/T Cayman (987)G87.40 6-Speed M/T Cayman S (987)CG1.00 7-Speed PDK 911 Carrera 2/S (997) - RoW, USA/CanadaG97.05 6-Speed M/T 911 Carrera 2/S (997) - RoW, USA/CanadaCG1.30 7-Speed PDK 911 Carrera 4/S (997) - RoW, USA/CanadaG97.35 6-Speed M/T 911 Carrera 4/S (997) - RoW, USA/CanadaG97.55 6-Speed M/T 911 Turbo (997) - World-Wide

CG1.50 7-Speed PDK 911 Turbo (997) - World-WideG97.90 6-Speed M/T 911 GT3 (997) - World-Wide

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Subject Page

General Information 2

Dual-mass Flywheel 2

Gear Ratios 3

Shift Mechanism 4

Transmission Housing 5

Gear Wheel Set 5

Input Shaft 5

Drive Shaft 6

Ring and Pinion 7

Synchronization 8

Gear Set Shell 9

Bearings 10

Lubrication 10

Limited-slip Differential 11

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Training Objective

Training objective After completing this training course,

you should be able to carry out repairs to a transmission

on your own, including all checks and adjustments You

should also be acquainted with the design and functions of

the Porsche manual transmission for the 911 Carrera

(997)

General Information

This brochure should help you to understand how the

Porsche manual transmission described here functions

and to familiarize yourself with its design This brochure is

not a repair manual and should only be used as a

reference aid for this training course This brochure

describes the transmission for the 911 Carrera (997)

Abbreviations

S1 = shim on taper roller bearing of differential on

crown wheel side

S2 = shim on taper roller bearing of differential opposite

crown wheel

S3 = shim for adjusting drive shaft

E = adjustment dimension

F = backlash

PSM = Porsche Stability Management

Pax = expansion force

Transmission Types

A completely new transmission has been developed forthe 911 Carrera and Carrera 4 (997)

Key objectives of this development were:

• Fewest possible transmission variants (Carrera and rera S)

Car-• Adaptation to engine power

• Easy shifting

• Reduction in transmission noise through the use ofground and honed gear wheels and cable shifting

Transmission Installed In Type

G97.01 911 Carrera S MY 2005 to 2008 G97.05 911 Carrera/S as of MY 2009G97.31 911 Carrera 4/4S MY 2006 to 2008G97.35 911 Carrera 4/4S as of MY 2009

to rattle or chatter This may result in disturbing noises,particularly at low engine speeds and high transmission oiltemperatures As with previous Porsche vehicles, the 911Carrera models have a dual-mass flywheel (DMF) toprevent these noises

Clutch

The familiar single-plate dry clutch with a diameter of 240

mm is used in the 911 Carrera model The clutch is adjusting, which extends the service life substantially andensures that the required pedal pressure remainsconstant The clutch linings are free of asbestos and lead

self-Notes:

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911 Carrera/S (997)

transmission, tan color

illustrates oil circuit.

Gear Ratios for Transmissions G97.01 and G97.31

1 = Number of teeth of first gearwheel in the power flow of the gear concerned

Z2 = Number of teeth of second gearwheel in the power flow of the gear

iZ = Gear ratio

iA = Axle ratio

V1000 = Calculated vehicle speed at engine speed of 1000 rpm

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Gear Ratio as of 2009 Model (G97.05 and G97.35)

The gear ratio for the 3rd gear has been changed to 1.56

for all manual transmissions for the 911 Carrera 2009

model

Gear Ratio Graph

Note !

The transmission diagram indicates general reference

val-ues based on a mean effective rolling radius The stated

values do not take account of deviations due to tire

toler-ances, changes in the rolling radius, wear and tire slip

Notes:

Shift Mechanism – Cable shifting

Similar with other Porsche vehicles, cable shifting is alsoused on the 911 Carrera This prevents the transfer of engine movements and vibration to the gearshift lever Incontrast to the previously employed shift linkage, shift andselector cables (which are able to withstand tension andpressure) form the connection between gearshift lever andtransmission The advantages of this system are reducedspace requirements, low weight and above all the effectiveprevention of the transfer of engine movements or

vibration to the gearshift lever, without impairing shiftingprecision

The repositioning of the deflection point at the gearshiftlever has enabled the 911 Carrera to achieve shorter shifttravel, reduced by approx 15%, while maintaining thesame required shifting forces (see Synchronization).Furthermore, play in the shift module under the gearshiftlever has been reduced, resulting in a more precisegearshifting gate

A – Outer shift lever to engage gear

B – Selector lever shaft to preselect gear

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