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

928 General 30
TIGHTENING TORQUE FOR AUTOMATIC TRANSMISSION
Threads
Description Material Torque
Nm (ftlb)
Location
Primary pump
to front cover Bolt M8
Bolt MlOxl
Bolt M8
Bolt M6
Plug M 27 x 1.5
8.8
10.9
8.8
10.9
-
20 (14)
14 (10)
13 19)
11 (8)
70 (51)
Plug
(converter)
Front cover
to transmission case
Support flange
to transmission case
Plug
(brake band B 1
mount)
Catch plate on range
selector shaft Bolt M6
M6
M6
8.8
8.8
8.8
8 (6)
8 (6)
8 (6)
8 (6)
8 (6)
Bolt
Leaf spring
to transmission case
Starter interlock
and backup light switch
to transmission case
1 Bolt
Range selector lever
to shaft 1 Bolt M6
Bolt M6
8.8
8.8
Secondary pump
to transmission case
Governor axial hold
on shaft Nut M6 8 6 (4.3)
Printed in Germany VI I I, 1984 Tightening Torques 30 0105

30
General 928
TIGHTENING TORQUE FOR AUTOMATIC TRANSMISSION
Location Description Threads Material Torque
Nm (ftlt
Lower cover
with reinforcement plate Bolt M5 5.8 4 (3)
Lower cover assy.
to transmission case Bolt M6 8.8 8 (6)
Plug (test connection
for modulating, governor
and operating pressure)
Plug M8xl - 13 (9)
Vacuum unit bracket
Kickdown solenoid valve
End plate on valve body
housing
Bokt
Solenoid
Bolt
M6 8.8 8 (61
M14x1.5 - 20 (14)
M4 8.8 3.3 (2.3)
End plate on drive
housing Bolt M4 8.8 3.3 (2.3)
Drive housing to valve
body housing
Valve body housing
to transmission
Bolt M5 4.8 0.15
(0.1 I)
Bolt M6 8.8 8 (6)
ATF filter to lower cover Bolt M5 8.8 4 (3)
d
0
30 - 0106 Tightening Torques
Printed in Germany

928 General Data
30
a
Tightening torques (automatic transmission)
Location
Threaded plug (ATF pan)
ATF pan to transmission case
Front converter casing to
transmission case
Carrier plate to converter
Rear transmission cas to
transmission case
Bearing assembly to
rear transmission case
Final drive to transmission
case
Collar nut (drive pinion)
ATF filler tube to ATF pan
ATF reservoir to ATF pan
Thread
MlOxl
ME
M8
M8
M 10
ME
M 10
M 26x 1.5
M 24
M6
* As of MY ‘92 (transmission type A28.18) = 450 Nm (332 ftlb),
Tightening Torque Nm (ftlb)
22 (12)
8 (5.9)
23 (17)
46 (34)
42 (31)
33 (24)
46 (34)
380* (280)
78 (58)
6 (4.4)
0
Tightening torques (automatic transmission) 30-0107
Printed in Germany - XXXI, 1993

928 Torque Converter
32
a
TOOLS
No. Description Special Tool Remarks
1 Transmission holder 9216
2 Grip plate 9301
3 Mandrel 9310
4 Depth gauge - Standard tool
a
Printed in Germany - VIII, 1984 Removing and Installing Torque Converter 32 101

32
Torque Converter 928
REMOVING AND INSTALLING TORQUE CONVERTER
I-
i .-.-. -.-.-.- .-.-.-. -‘-‘-‘-‘-‘-
/I-. I
i
y.<-’
i
.c’
0-I
@-9
1
4123
/
! I
:/- j
a
32-102 Removing and Installing Torque Converter
Printed in Germany

928
Clutch, Automatic Torque Converter
32
NC Description
!tY.
I
i
4
a 5
l I5
Mounting bolt
Panhead bolt 8
Washer 8
Front converter
casing
Torque
converter
lutomatic
transmission
T
6
1
1
1
-
Removing Note When: Installing
Lift out carefully
with Special Tool
9301
Tightening torque:
46 Nm (34 ftlb)
Tightening torque:
23 Nm (17 ftlb)
Renew if badly worn
or if particles are
found in ATF
Lubricate drive flange
and bearing pin with
MoS multi-purpose
i
gre se. Place
transmission upright
and insert carefully
using Special Tool
9301. Note
installation depth.
Printed in Germany - XVI,1987
Removing and Installing 32 - 103
Torque Converter

32
Clutch, Automatic Torque Converter 928
a
/
NOTES ON REMOVING AND INSTALLING r
I'
Removinq
l.Remove transmission.
./ ,. ,J
,/‘” -yp? pf./
w / ;gzp,$:
2.Using Special Tool 9216, attach
transmission to assembly support.
6.Attach Soecial Tool 9301 to
torque converter and carefully
lift out converter.
3.Place transmission upright and
working through the openings in ~~
the converter casing, remove
converter mounting bolts. !
4.Remove mounting bolts for
converter casing and remove
casing. Installinq
Note:
5.Measure installation depth of
converter and make a note for
reassembly.
Up to '86 models = approx. 16 mm
'87 models onward = approx. 28 mm
If the ATF smells burnt or if the
fluid contains particles of pad
material, torque converter and ATF
cooler must be rinsed.
If particles of metal are found in
the ATF pan, the torque converter
must be replaced. Rinsing will not
remove all metal particles and
damage to the transmission may
result.
32 - 104 Removing and Installing
Torque Converter Printed in Germany

928 Clutch, Automatic Torque Converter
32
l.Rinse torque converter with
Special Tool 9310. To rinse, fill
converter with approx. 11 of
kerosine, insert the rinsing pin
and use a hand drill to turn the
pin at low speed. Then drain
kerosine off through drain plug.
Repeat rinsing 2 - 4 times until
the kerosine drained from the
converter is clean.
2.Attach Special Tool 9301 to
torque converter.
3.Coat drive flange and bearing
pin of converter with MoS2
multi-purpose grease.
4.Place transmission upright and
carefully insert converter,
turning unit in both directions
to engage the teeth.
5.Check installation depth of
converter.
Up to '86 models = approx. 16 mm
'87 models onward = approx. 28 mm
Printed in Germany - XVI,1987 Removing and Installing 32 - 105
Torque Converter

928 Automatic Transmission/Controls, Case
37
REMOVING AND INSTALLING SELECTOR LEVER COVER FRAME
Removing
1. Remove selector lever grip and take off
rubber boot.
2. Move selector lever to position “2” and
push rear locking bar forward against stop
with a suitable tool (e. g. scribe).
3. Move selector lever to position “R”,
disconnect gate and push forward as far as
possible.
4. Push front locking bar forward against stop
with a suitable tool (e. g. scribe).
5. Move selector lever to position “P” and
press out cover frame carefully with a
suitable screwdriver applied at the left rear
corner.
6. Move selector lever to position “N” and
remove frame inclined toward rear.
Installing
1. Move selector lever to position “3”.
2. Push gate in frame forward all the way,
3. Install cover frame in correct position and
move selector lever to position “P”.
4. Push cover frame forward and move right
side to correct installed position (this is
done by lifting left rear corner slightly
and pushing down on right side).
5. Push down on left rear corner until frame
fits in center console correctly.
Printed in Germane - VIII, 1984
Removing and Installing Selector Lever 37-101
Cover Frame

37
Automatic Transmission/Controls, Case 928
6. Position selector lever between “R” and
“P”, disconnect gate on selector lever and
push forward.
7. Push front locking bar toward rear until it
engages.
8. Move selector lever to position “3” and
push rear locking bar toward rear until it
engages.
a
9. Attach gate in selector lever, install
rubber boot in correct position and
install selector lever grip.
IO. Move selector lever in and out of all
positions and make sure that cover frame
fits properly.
a
a
A - Locked
6 - Unlocked
37 - 102 Removing and Installing Selector Lever Cover Frame
Printed in Germany