Porsche 928 - Instruction manual

Workshop Manual
l
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
Maintenance, Self-diagnosis
Group
03
Engine
Engine, Crankcase
Engine, Crankshaft, Pistons
Engine, Cylinder Head and Valve Drive
Engine, Lubrication
Engine, Cooling
Fuel Supply
Air Flow Controlled Fuel injection
Exhaust System/Emission Contrds
Starter, Power Supply, Cruise Control
Ignition System
10
13
15
17
19
20
24
26
27
28
Transmission
Chassis
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
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
Radio
Windshield Wipers and Washer
Exterior Lights, Lamps, Switches
Interior Lights
Wiring
90
91
92
94
96
97
Printed in Germany - XX, 1997

928 Table of contents Volume III
a
General Data
Technical data
Tightening torques
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 ....................
Checking operation ...........................
Checking operation (87 models onward) ................
Troubleshooting. ............................
Removing and installing shift valve casing ...............
Disassembling and assembling shift valve housing ..........
Disassembling and assembling shift valve casing (‘87 models onward)
Removing and installing lower cover ..................
Disassembling and assembling lower cover ..............
Replacing ATF and filter ........................
Flushing ATF cooler and lines .....................
Removing and installing governor ...................
Checking governor ...........................
Removing and installing vacuum modulator ..............
Removing and installing primary pump. ................
38-101
38-l 10
38-11 Oa
38-111
38-123
38-l 25
38-130a
38-131
38-133
38-137
38-141
38-143
38-145
38-147
38-149
Page
30-0101
30-0105
-
Table of contents 1
Prlnwdin 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 ......................
Disassembling and assembling final drive ..................
Disassembling and assembling differential ..................
Disassembling and assembling bearing assembly ..............
Disassembling and assembling bearing assembly / Determining thickness of
shims for bearing assembly ..........................
Adjusting drive pinion and ring gear. .....................
Adjusting drive pinion and ring gear. .....................
Adjusting drive pinion and ring gear. .....................
Adjusting drive pinion and ring gear. .....................
Adjusting drive pinion and ring gear. .....................
Adjusting drive pinion and ring gear. .....................
Disassembling and assembling central tube .................
Checking central tube .............................
PSD-Diagnosis I Troubleshooting .......................
39-l 01
39-107
39-113
39-l 19
39-123
39-125
39-127
39-128
39-130
39-133
39-135
39-137
39-139
D39-201
2
l
Table of contents
Printed In Genany - XXXV. 1999

928
General Data
30
a
4 - SPEED AUTOMATIC TRANSMISSION (UP TO '86 MODELS)
1 - Front converter casing 2 - Automatic transmission
a 3 - Final drive
Transmission Type
A 28.01
A 28.02
A 28.03
A 28.04
A 28.05
0 A 28.06
A 28.07
A 28.08
A 28.09
A 28.11
installed in
928 S, USA series / '83 and '84 models for Japan
928 S, Special option for Europe / rest of the
world, '84 models
928 S, Special option (M 251) Europe / rest
of the world 3/84 onward (as 28.02, but
rear axle transmission ratio 13 : 33)
928 S, USA series / '85 models for Japan
928 S, Special option Europe / '85 models
rest of the world
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)
928 S, USA series / '86 models for Japan
928 S, Special option Europe / '86 models
rest of the world
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)
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
Technical Data
General Data 920
0
4-speed automatic transmlsslon (‘87 models onward)
1 - Front converter casing
3 - Final drive 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
Printed in Germany - XXXI, 1993

928 General Data
30
a
Technical Data
Tmsmlsslon DeslgnatTon
1
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
Printed in Germany - XXXI, 1993
30 - 0102a

30
General Data 928
Technical Data
Transmlssion numbers (12 dlglts)
A2814
T
Index for varlants
wlthln the assembly number
0 = no differential
1 = normal differential
2 = ZF limited slip differential
3 = proportional slip differential
Model year Serlal
number
J = 1988 e.g. 00903
K = 1989
L = 1990
M = 1991
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
Ratios
1st gear
2nd gear
3rd gear
4th gear
RDckw&tsgang
Final drive
Final drive ratio
(Stall speed)
Capacity, rear
axle final drive
Oil grade
Capacity, auto.
unl with
converter
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
368
2941
I,44
1,oo
5,14
Drive pinion without hypoid displacement
m
A 28/t 6
3,87
2,25
I,4
1,oo
5,59
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)
A 28.01 = A 28.02/03/05/06/08/09/l 1 =
2200...2600rpm 2200...2600rpm
up to MY ‘86 = approx. 2.7 I
from MY ‘87 to ‘90 = approx. 3.0 I
MY ‘91 = 2.3 I*
as of MY ‘92 = 1.9 I
Multigrade transmission oil 75 W 90 to MIL L 2105 B or
API classtication GL5
Total capacity = approx. 8.01 (‘87 models onward,
approx. 9.31). Capacity for fluid change with 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
Printed in Germany - XXXI. 1993