Porsche training p30g drivetrain repair sports car

Transmission – G96.00 - 911 Carrera 2 996 The 6th gear has been configured to allow the maximumpossible vehicle speed to be reached.. Transmission – G96.01 - 911 Carrera 2 996 &G86.20 -

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AfterSales Training

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Student Name:

Training Center Location:

Instructor Name:

Date: _

Important Notice: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 tent Some equipment and technical data listed in this publication may not be applicable for our market Specifications are subject to change without notice.

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

© 2007 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 TM , Tiptronic®, VarioCam®, PCM®, 911®, 4S®, and

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Description Section

Transmission Type Designations 1

Six-Speed Transmissions – G96.00/01/30/31, G86.20 2

Final Drive Setup 3

Conversion Charts 4

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

1989 G50.00 5-Speed M/T 911 Carrera - RoW

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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Model Transmission Technical Installed In

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/Canada

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1999 A86.00 5-Speed A/T Boxster (986)

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-Wide

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

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Subject Page

General Information 3

G96.00 - 911 Carrera 2 (996) Transmission 3

G96.01 - 911 Carrera 2 (996)/G86.20 - Boxster S (986) Transmission 4

Transmission Cutouts 6

Transmission Ratios 8

Gears 9

Synchronization 10

Final Drive 10

Limited-slip Differential 10

Shifter 11

Internal Shifting 12

Transmission Housing 13

Viscous Coupling 14

Front Differential 15

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Notes:

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General

The 911 Carrera 2/4 (996) and Boxster S (986) (M.Y

2000-04) came equipped with a 6-speed Manual

Transmis-sion or optional Tiptronic automatic transmisTransmis-sion

A completely new transmission was developed for use in

the 911 Carrera (996) and subsequently the Boxster S

(986) The most important development objectives were:

l One transmission variant worldwide

l Adaptation to the engine power

l Smooth shifting

l Reduction of transmission noise by means of ground

gearwheels and cable shifting

Manual Transmission Types:

This section describes the manual transmission for the

911 Carrera/4 (996) The 6-speed transmission for the

Boxster S (986) M.Y 2000-04 is identical except for the

installation position of the ring gear

Transmission – G96.00 - 911 Carrera 2 (996)

The 6th gear has been configured to allow the maximumpossible vehicle speed to be reached The relatively short1st gear relieves the load placed on the clutch when thevehicle moves off and also ensures a favorable crawlingspeed The reverse gear has been considerably

shortened

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Transmission – G96.01 - 911 Carrera 2 (996) &

G86.20 - Boxster S (986)

Additional 3rd Bearing on Input Shaft, See Arrow

The manual transmission for the rear wheel drive vehicle

and the four-wheel drive vehicle is based on the previous

911 (993) generation transmission The manual

transmis-sion has been adapted to the higher engine torque of the

911 3.6 l engine with the dimensions and transmission

ratios remaining unchanged The necessary higher

dynamic strength of the components has been achieved

through the use of higher alloy steels and precision shot

blasting at the pinion shafts The aluminum die-cast

hous-ing has been further optimized with regard to acoustics

and vibration and has been adapted to the new installation

position due to the standardization of the transmission

mounts (manual and Tiptronic)

The efficiency has been improved by reducing the drag

factor through decreased preloading on the tapered roller

bearings For vibration reasons, the input shaft has been

converted from a 2-bearing to a 3-bearing arrangement

(see arrow)

Improved transmission cooling through directed air flow in

the underbody of the vehicle, an open ventilator with

labyrinth sealing and waxed sealing rings completes the

optimization

911 Carrera 4 (996) Driveline Configuration

Power is transmitted to the front axle from the sion via a single-piece drive shaft and a central shaft to theviscous multi-disc clutch integrated in the front-axle finaldrive

transmis-The advantages of this concept-drive shaft plus centralshaft are the reduced weight and the increased ease of repair For example, after the drive shaft has beenremoved, it is then possible to remove the transmissionwithout the engine

As a standard feature, the new 911 Carrera 4 (996) is fitted with a six-speed manual transmission This transmis-sion was redesigned for the 911 Carrera 4 with cableshifting and both units are largely identical

The drive shaft has been extended towards the front forthe all-wheel drive of the front axle The shaft emergesthrough an additional opening in the front section of thetransmission housing and drives the front axle via a singlepiece drive shaft and a central shaft

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Additional 3rd Bearing on Input Shaft, See Arrow

The manual transmission for the rear wheel drive vehicle

and the four-wheel drive vehicle is based on the previous

911 (993) generation transmission The manual

transmis-sion has been adapted to the higher engine torque of the

3.6 l engine with the dimensions and transmission ratios

remaining unchanged The necessary higher dynamic

strength of the components has been achieved through

the use of higher alloy steels and precision shot blasting at

the pinion shafts The aluminum die-cast housing has been

further optimized with regard to acoustics and vibration

and has been adapted to the new installation position due

to the standardization of the transmission mounts (manual

and Tiptronic)

The efficiency has been improved by reducing the drag

factor through decreased preloading on the tapered roller

bearings For vibration reasons, the input shaft has been

converted from a 2-bearing to a 3-bearing arrangement

(see arrow)

Improved transmission cooling through directed air flow in

the underbody of the vehicle, an open ventilator with

labyrinth sealing and waxed sealing rings completes

the optimization

Notes:

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G96.00 Transmission Cutout

G96.01/G86.20 Transmission Cutout

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Transmission Ratios – 911 Carrera 2/4 (996) G96.00/30

\

Gear Versus Road Speed Graph

Transmission Ratios – 911 Carrera 2/4 (996) G96.01/31

Transmission Ratios – Boxster S (986) G86.20

G96.00/30 & G86.20 Transmission Ratio

Z1 = Number of teeth in 1st gearwheel in power flow of corresponding gear

Z2 = Number of teeth in 2nd gearwheel in power flow of corresponding gear

iz = Transmission ratio

ia = Final drive ratio

V1000 = Calculated vehicle speed at 1,000 rpm engine speed

V6000 = Calculated vehicle speed at 6,000 rpm engine speed

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Gear Sets

The transmission is a two-shaft transmission with an

over-head drive shaft and hypoid drive assembly The loose and

fixed gearwheels of all forward gears have been ground

and honed to reduce noise to a minimum The shifting

gearwheel for the reverse gear has been shaved Pairing

of the gearwheels was not necessary

All loose gearwheels have needle roller bearings The fixed

gearwheels for the reverse gear, 1st gear, and 2nd gear

form part of the input shaft The distance between the

axles of the input and output shafts is 87 mm The reverse

gear is synchronized and can therefore be smoothly

engaged even when the vehicle is coasting slowly

forwards

Gear Sets

Reverse Gear Components

The reverse gear is located in the transmission case

cover The intermediate gearwheel of the reverse gear (1)

Bearing Method

The input and output shafts are mounted radially and axially in the transmission case by means of sealed doubleangular contact ball bearings The output shaft is mounted

in the transmission case cover by means of cylindricalroller bearings and the input shaft is mounted using aroller bearing sleeve

Input and Output Shafts - Boxster G86.20 and 911 (996 (G96.01/31 have an additional bearing in this area (red arrow).

Notes:

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Synchronization, 1st/2nd Gear

As with the 911 Carrera (993), the G 96 transmission has

double cone synchronization for 1st and 2nd gear The

major advantage of this synchronization is that the shifting

forces are reduced by approx 30 - 40 % compared to

single cone synchronization

Functioning

The synchronizing ring (2) and friction ring (3) rotate at the

same speed as the guide sleeve (4) and shift sleeve (5)

irrespective of the vehicle speed (drive shaft) The loose

gearwheel with clutch body (6) and the tapered ring (1)

rotate at the same speed as the engine

If, during the shifting process, the shift sleeve is moved

axially along the guide sleeve, a moment of friction is

produced between the synchronizing ring and tapered ring

at the around the outside diameter and between the

friction ring and tapered ring around the inside diameter

This moment of friction decelerates (1 - 2 shifting) or

accelerates (2 - 1 shifting) all parts rotating at the same

speed as the engine Doubling the number of friction

surfaces considerably reduces the shifting forces

Synchronization, 3rd - 6th and R Gear

Synchronization for gears 3 - 6 and for the reverse gear is

identical to single cone synchronization The synchronizing

rings for gears 3 - 6 are identical and have a molybdenum

Gear Retention

Gear retention is achieved by beveling the clutch bodytoothing and shift sleeve toothing When the torque istransmitted, the beveled surfaces of the shifting sleeveand the clutch body are pressed against each other sothat the shifting sleeve is moved to the clutch body orloose gearwheel

Final Drive

Ring and Pinion

The drive set is a hypoid drive This means that the centeraxis of the crown wheel is 12 mm above the center axis ofthe drive shaft Hypoid drives can (with the same crownwheel size) transmit relatively high torques since the teeth

of the drive shaft have designed to be more robust In addition, the modified crown wheel bearing can be used atlower diffraction angles along the drive shafts The driveshaft and crown wheel are toothed using the Oerlikonmethod The drive shaft has been hollow-drilled to reduceweight The diameter of the crown wheel is 196 mm Theadjusting dimension E is 65 mm

Limited-slip Differential

As standard equipment, the 911 Carrera 4 (996) has aPorsche Stability Management (PSM) A mechanicallimited-slip differential would have a detrimental effect onthe functioning of the PSM The 911 Carrera 4 (996) cannot be equipped with a mechanical limited-slip differen-tial

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