Porsche 928 - Manuel d'instructions

Workshop Manual

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

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

Transmission

Chassis

Clutch, Controls 30

Torque Converter

Manual Transmission, Controls, Case

Manual Transmission, Gears, Shafts 35

Automatic Transmission, Controls, Case

Automatic Transmission, Gears, Valve Body

Differential, Transaxle System 39

Front Wheel Suspension 40

Rear Wheel Suspension, Axle Shaft

Wheels, Tires, Alignment

Antiblock System

Brakes, Mechanical 46

Brakes, Hydraulics

Steering

Body-Front Section

Body-Center Section 51

Body-Rear Section

Lids

Doors

Hardtop 61

Bumpers 63

Glasses, Window Control 64

Exterior Equipment 66

Interior Equipment

Seats

Seat Covers

Heating,

Heater 80

Ventilation, Ventilation 85

Air Condition

Air Conditioner

Electrics

Instruments, Fuel Gauge, Alarm System

Radio

Windshield Wipers and Washer

Exterior Lights, Lamps, Switches

Interior Lights

Wiring

Printed in Germany - XX, 1997

928 Table of contents Volume III

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. .....................

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

Table of contents

Printed In Genany - XXXV. 1999

928

General Data

4 - SPEED AUTOMATIC TRANSMISSION (UP TO '86 MODELS)

1 - Front converter casing 2 - Automatic transmission

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)

Printed in

Germany-XX,1988

Technical Data

30 - 0101

Technical Data

General Data 920

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

Technical Data

Tmsmlsslon DeslgnatTon

A 28 02 12 1 6 E 05065

-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

722316 02.~

A28.01

7222702501 72231602...=

A28.07

722 270 14

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

722 318 02...=

A 28.08/09

7222703401 72236003...=

A28.18

Technlcal Data

Printed in Germany - XXXI, 1993

30 - 0102a

General Data 928

Technical Data

Transmlssion

numbers

(12 dlglts)

A2814

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

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

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

Technlcal Data 30 - 0103

Printed in Germany - XXXI. 1993

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