Professional Documents
Culture Documents
Volume II - Transmission
This Workshop Manual describes all of the important operations for which special instructions are required to
assure proper completion. This manual is essential for shop foremen and mechanics, who need this
information to keep the vehicles in safe operating condition. The basic safety rules, of course, also apply to
repairs on vehicles without exception.
Only those repair jobs deviating from those of vehicle type 924 are described in the 944 Workshop Manual.
Refer to the 924 Workshop Manual for all other information.
The information is grouped according to repair numbers which are identical to the first two digits of the
warranty job codes.
The repair group index, list of contents and the register tabte are quick guides to find information in the
manual. The layout drawings in this manual are numbered in the order of disassembling and, if necessary,
also have information on assembly or installation and application of special tools.
Descriptions of design and function can be found in the service training course reference material.
This Workshop Manual will be kept up to date with Technical Information Bulletins, which will be made part
of the manual from time to time. We recommend that these bulletins be filed in the standard type folder
provided for this purpose.
Printed in Germany
Technical Data
Repair Groups
Page 0.1
Group
Maintenance, Self-diagnosis
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 Controls
Starter, Power Supply, Cruise Control
Ignition System
DME Diagnosis
10
13
15
17
19
20
24
26
27
28
Transmission
Clutch, Controls
Torque Converter
Manual Transmission, Controis, Case
Manual Transmission, Gears, Shafts
Autornatic Transmission, Controls, Case
Automatic Transmission, Gears, Valve Body
Differential, Transaxle System
Chassis
40
42
44
45
46
47
48
Body
Body-Front Section
Body-Center Section
Body-Rear Section
Lids
Doors
Hardtop
Bumpers
Glasses, Window Control
Exterior Equipment
Interir Equipment
Seats
Seat Covers
Airbag Diagnosis
50
51
53
55
57
61
63
64
66
68
72
74
Heating,
Ventilation,
Air Condition
Heater
Ventilation
Air Conditioner
80
85
87
Electrics
90
91
92
94
96
97
30
32
34
35
37
38
39
944
Blank Page
944
Table of contents
volume II
Page
General data
Technical data (Type 016 J and 016 K)
Technical data (Type 016Jand 016 K, Mod. 85/2 onward)
Technical data (Type 016J/K and 083 D)
Technical data(Type 083 F)
Tightening torques (Type 016 J and 016 K)
Technical data, clutch
30 - 01
30 - 02
30 - 03
30 - 04
30 - 05
30 - 07
Clutch, Control
Checking clutch play, adjusting clutch spring
Checking condition of clutch drive disk
Checking release travel, bleeding hydraulic clutch system
Clutch, removing and installing
Clutch control, disassembling and assembling
Checking drive disk
Checking pressure plate
Overhauling slave cylinder
30 - 1
30 - 2
30 - 3
30 - 5
30 - 13
30 - 16
30 - 17
30 - 19
32 - 1
32 - 2
32 - 3
34 - 1
34 - 4
34 - 5
34 - 7
34 - 9
34 - 15
34 - 27
34 - 31
34 - 39
Table of contents
35 - 1
35 - 7
volume II
Table of contents
944
Page
Automatic transmission
Technical data (Type 087 M and 087 N)
Identification code for transmission (Type 087 M and 087 N)
Technical data (Type 087 M and 087 N)
Position of the shift elements in the various selector lever positions or
gears (Type 087 M and 087 N)
Planetary gear with shift elements (Type 087 M and 087 N)
Tightening torques (Type 087 M and 087 N)
Selector lever cable, removing and instailing (Type 087 M and 087 N)
Throttle and control pressure cable, removing and installing (Type 087 M and 087
N)
Adjusting throttle and control pressure cable (Type 087 M and 087 N)
Functional test(Type 087 M and 087 N)
Troubleshooting table (Type 087 M and 087 N)
Transmission, removing and installing (Type 087 M and 087 N)
37 - 01
37 - 02
37 - 03
37 - 04
37 - 05
37 - 07
37 - 1
37 - 8a
37 - 11
37 - 13
37 - 17
37 - 18
38 - 1
38 - 2c
38 - 3
38 - 7
38 - 9
38 - 11
38 - 19
38 - 21
38 - 22a
38 - 23
38 - 27
38 - 33
38 - 35
38 - 39
38 - 45
38 - 55
38 - 57
38 - 59
39 - 1
39 - 5
Table of contents
944
Table of contents
volume II
Page
Adjusting pinion and ring gear (Type 016 J and 016 K)
Tightening torques (Type 087 M and 087 N)
Checking oil level in rear final drive (Type 087 M and 087 N)
Final drive, disassembling and assembling (Type 087 M and 087 N)
Differential, disassembling and assembling (Type 087 M and 087 N)
Limited slip differential (40%), disassembling and assembling
Adjusting drive set (Type 087 M and 087 N)
Central pipe, removing and instaIling (Type 087, M and 087 N)
Central pipe, disassembling and assemblilig (Type 0,87 M and 087 N)
Checking central pipe (Type 087 M and 087 N)
Adjusting dampers (Type 087 M and 087 N)
Table of contents
39 - 11
39 - 101
39 - 103
39 - 105
39 - 119
39 - 122a
39 - 123
39 - 135
39 - 143
39 - 145
39 - 146
30
30 - 00
Generel
944
Blank Page
944
Generel
30
Code
016 K
QM
Standard
016 K
8Q
Printed in Germany
30 - 01
30
General
944
5-speed manual transmission 016J and 016K (as from Model 85/2)
Type
Identification
code
Equipment
Installed in
Model year
016J
5Y
5-speed without
limited slip differential
85/2...88
88
016J
5Z
5-speed with
limited slip differential
85/2...88
88
016K
5S
USA/Japan
85/2...87
016K
7V
USA/Japan
85/2...87
016J
ASG
Worldwide
89...91
016J
ASH
Worldwide
89...91
30 - 02
944
30
Generel
Type
Code
Installed in
083 D
AGP
Woldwide
083 D
AGR
Woldwide (with
limited-slip
differential)
With the exception of a few modifications in its design and as regards repair
the 083 D transmission is the same as the 016 R Turbo transmission.
The most important modifications are:
- no transmission-oil pump is available
- final drive ratio increased to 9 : 35
- transmission casing with machined recess for ring gear
- design distance "Ro" 58.15 mm
Technical Data
(Type 083 D)
30 - 02a
30
General
944
Type
Code
Equipment
Installed in:
Model Year
083F
A0S
5-speed
without lock
944 S 2 worldwide
except Switzerland
1989/90/91
083F
A0T
5-speed
with lock
944 S 2 worldwide
except Switzerland
1989/90/91
083F
ASV*
944 S 2 Switzerland
1989/90/91
083F
ASW*
944 S 2 Switzerland
1989/90/91
30 - 02b
944
General Data
30
General Data
083 D (AGP/AGR)
Ratios
1st gear
10 : 36
i = 3,6000
10 : 35
i = 3.500
2nd gear
16 : 34
i = 2,1250
17 : 35
i = 2.059
3nd gear
24 : 35
i = 1,4583
25 : 35
i = 1.400
4nd gear
28 : 30
i = 1,0714
29 : 30
i = 1.034
5nd gear
35 : 29
(37 : 27
i = 0,8286
i = 0,7297)
35 : 29
i = 0.829
Reverse gear
12 : 42
i = 3,5000
12 : 42
i = 3.500
Final drive
9 : 35
Power transmission
Filling capacity
Approx. 2.0 liters hypoid transmission oil SAE 75 W 90 to API Class GL5 or
MIL-L 2105 B, or SAE 80 to API Class GL 4 or MIL-L 2105 (refer to page 34 - 7)
i = 3.889
30 - 03
30
General
944
Ratios
1st gear
10 : 35
= 3.500
2nd gear
17 : 35
= 2.059
3nd gear
25 : 35
= 1.400
4nd gear
29 : 30
= 1.043
5nd gear
36 : 28
= 0.778
Reverse gear
12 : 42
= 3.500
Final Drive
8 : 31
Power transmission
Filling capacity
Approx. 2.0 liters hypoid transmission oil SAE 75 W 90 to API Class GL5
or MIL-L 2105 B, or SAE 80 to API Class GL or MIL-L 2105 (refer to page 34 - 7).
30 - 04
= 3.875
944
30
General Data
Location
Description
Threads
Material class
Tightening torque
Nm (ft.lb)
Plug
M 24
24 (17)
Plug
M 24
24 (17)
Hexagon head
screw
M6
8.8
8 (6)
Hexagon head
screw
M8
8.8
24 (17)
Hexagon head
screw*
M 10
8.8
70 (51)
Fillister head
screw
M8
8.8
24 (17)
Hexagon head
screw*
M 10
8.8
70 (51)
Threaded
bushing
M 18
30 (22)
Stop screw
M 14
8.8
30 (22)
30 - 05
30
General Data
944
Location
Description
Threads
Material class
Tightening torque
Nm (ft.lb)
Reversing lever to
end shield
Cross-recessed fillister
head screw
M 10
8.8
35 (25)
Hexagon head
screw with
collar
M8
8.8
24 (17)
Screw
M8
8.8
24 (17)
Side transmission
cover to transmission case
Hexagon head
screw
M8
10.9
24 (17)
Hexagon head
screw
M 10
12.9
90 (66)
Switch
M 18
42 (42)
Speedometer
bushing to transmission case
Speedometer
bushing
M 18
42 (30)
Crankshaft to flange
Hexagon
socket screw
M8
12.9
42 (30)
30 - 06
944
General
General Data
Clutch
Design
Pressure plate
Clutch disc
Printed in Germany
Technical Data
30
30 - 07
30
General
944
Location
Description
Threads
Material
Torque
Nm (ft lb)
Bolt
M7
8.8
15 (11)
Bolt
M8
25 (18)
Flywheel to crankshaft
Bolt
M 10
10.9
90 (65)
Clutch housing to
engine
Bolt
M 12
8.8
75 (54)
Bolt
M 10
8.8
42 (30)
Bolt
M6 x 35
8.8
9.5 (7)
Nut
M6
7.5 (6)
Bolt
M6
8.8
8 (6)
Slave cylinder to
clutch housing
Bolt
M8 x 28
8.8
21 (15)
Master cylinder to
firewall
Nut
M8
21 (15)
Coupling
M 12
Clamp bolt
M 10 x 46
12.9
80 (58)
Bolt
M 10 x 35
8.8
42 (30)
CLUTCH
30 - 08
Technical Data
16 (11)
Printed in Germany
944
30
General
Location
Description
Threads
Material
Torque in
Nm (kpm)
Bolt
M 12 x 75
10.9
85 (8.5)
M 12 x 80
10.9
85 (8.5)
M 10 x 60
8.8
42 (4.2)
Bolt
M 10
8.8
46 (4.6)
Mount to bracket
Bolt
M8
8.8
25 (2.5)
Bracket to
transmission
Bolt
M8
10.9
25 (2.5)
Bolt
M 10
8.8
46 (4.6)
Transmission mount
to transmission carrier
Bolt
M8
8.8
23 (2.3)
Bolt
M8
23 (2.3)
Bracket to transm.
Bolt
M8
23 (2.3)
Joint rod to
transmission case
Ball-ended bolt
M8
9 S Mn 28 K
14 (1.4)
Nut
M8
8.8
21 (2.1)
Shift rod
Bolt
M8
9 S Mn 28 K
21 (2.1)
Bolt
M 8 x 12
8.8
21 (2.1)
Intermediate shift
lever to shift shaft
Bolt
M8
SHIFT
22.5 (2.25)
Technical Data
30 - 09
30
30 - 0
Clutch/Controls
944
Blank Page
944
Clutch/Controls
30
30 - 1
30
Clutch/Controls
944
Size new
Wear limit
30 - 2
18 mm
34 mm
Printed in Germany
944
Clutch / Controls
30
If distance is less than 15 mm there can be no guarantee that clutch disengages fully.
Possible Causes:
BLEEDING CLUTCH
General Information
The use of a pressure bleeder is recommended.
1. Fill tank with brake fluid to upper edge.
Remove restrictor sleeve. Connect bleeder.
Printed in Germany
30 - 3
30
Clutch / Controls
944
30 - 4
Bleeding Clutch
Printed in Germany
944
Clutch / Controls
30
Note
When performing operations on the transaxle
system that involve rotating or shifting the
transaxle tuebe, always wear leather gloves
to avoid injuries.
Removing
1. Disconnect ground wire at battery. Disconnect
round wire connecting body with clutch housing.
Printed in Germany
30 - 5
30
Clutch / Controls
944
30 - 6
Printed in Germany
944
Clutch / Controls
30
30 - 7
30
Clutch / Controls
944
Printed in Germany
944
Clutch / Controls
30
Printed in Germany
30 - 9
30
Clutch / Controls
Installing
1. Check flywheel, starter gear ring, pilot bearing in
flywheel, crankshaft seal, release bearing, guide
sleeve, release lever, pressure plate and clutch
disc for wear or damage.
944
30 - 10
Printed in Germany
944
Clutch / Controls
30
11. Place selector rod protective tube in transmission case. Replace a selector rod protective
tube, if retainer is deformed excessively.
Install transmission.
Push selector rod protective tube forward until
retainer engages in transmission case.
Mount selector rod on intermediate shift lever.
Note
To avoid tension in engine, transmission and
central
tube, when installing in car tighten central tube to
clutch housing mounting bolts only after bolting the
engine and transmission.
Printed in Germany
30 - 11
30
Clutch / Controls
944
30 - 12
Printed in Germany
944
Clutch / Controls
30
Printed in Germany
30 - 13
30
Clutch / Controls
944
Note When:
No.
Description
Qty.
Bolt
Torque: 21 Nm
(15ft lb)
Lockwasher
Replace. if
necessary
Slave cylinder
Bolt 6 x 35
Nut (locknut)
Cap
Clutch housing
Mount clutch
housing and
release lever
together on engine/
release bearing
before installing
release lever
shaft
Release lever
Lubricate
bearing surfaces
with a white
solid lubricating
paste
(AOS 126 0006)
30 - 14
Removing
Installing
Special
Instructions
Do not operate
clutch pedal after
removing cylinder
(line connected)
Tighten after
pushing in release
lever shaft
correctly
Refer to point 8
Push in against
stop in correct
position - machined
surface faces
bolt 4
Refer to point 8.
Do not use force!
Move release lever
back and forth
slightly through
sight hole
Printed in Germany
944
30
Clutch / Controls
Note When:
No.
Description
Qty.
10
Bolt
Torque: 9.5 Nm
(7 ft lb)
11
Guide sleeve
Coat sliding
surfaces with
multi-purpose
grease MoS2
12
Needle bearing
Printed in Germany
Removing
Installing
Special
Instructions
30 - 15
30
Clutch / Controls
944
Note
Clutch liners cannot be replaced.
30 - 16
Printed in Germany
944
Clutch / Controls
30
Blank Page
30 - 17
30
Clutch / Controls
944
30 - 18
Blank Page
944
Clutch / Controls
30
Printed in Germany
30 - 19
30
Clutch / Controls
944
Note When:
No.
Description
Qty.
Circlip
Push rod
Rubber cover
Retainer
Piston
Cup
Replace. apply
very thin coat of
brake cylinder
paste
Spring
Position correctly
Dust cap
Bleeder screw
10
Clutch slave
cylinder
30 - 20
Removing
Installing
Special
Instructions
Replace. curved
surface faces in.
Make sure of
perfect fit
Replace
Always clean
with alcohol. apply
very thin coat of
brake cylinder
paste in cylinder
bore
Printed in Germany
944
Torque Converter
32
32 - 1
32
Torque Converter
944
Note:
Cut angle or notch end of hose before inserting, so
that ATF can flow into hose.
32 - 2
Printed in Germany
944
Torque Converter
32
CORRECT
WRONG
2. Place converter on one-way clutch support carefully; not tilting the converter.
3. Engage converter in splines by turning back and
forth slightly.
Note:
The pump shaft has a tapered spline to make it
easier to engage the drive dog in the converter and
oil pump.
32 - 3
34
944
www.9ss1.dk/porsche944
34 - 0
Blank Page
944
34
Removing
1. Remove catalytic converter together with muffler.
Printed in Germany
34 - 1
34
944
Installing
34 - 2
Printed in Germany
944
34
Printed in Germany
34 - 3
34
944
944
34
34 - 4 a
34
944
34 - 4 b
Printed in Germany
944
34
Printed in Germany
34 - 5
34
944
www.9ss1.dk/porsche944
34 - 6
Blank Page
944
34
Note
The fluid level in the transmission housings
used in production is approx. 6 to 8 mm
below the filler neck when 2 liters of transmission oil have been filled in.
1 - Drain plug
2 - Filler plug
2. Drain transmission oil of a car parked
on level ground or floor and transmission having operating temperature.
3. Clean filler and drain plugs, and torque
to 24 Nm.
4. Pour in transmission oil with car parked
on level surface.
34 - 7
34
34 - 8
944
Blank Page
944
34
TOOLS
No.
Description
Special Tool
Assembly stand
VW 540
Assembly sleeve
9178
Printed in Germany
Remarks
34 - 9
34
34 - 10
944
Printed in Germany
944
34
Note When:
No.
Description
Qty.
Threaded sleeve
Gasket
Spring
Sleeve
Bolt
Washer
Cover
Gasket
Selector shaft
assembly
10
Dowel sleeve
11
Bolt
12
12
Gear carrier
assembly
13
Bolt
14
Flange shaft
15
16
Cover
17
Differential
Printed in Germany
Removing
Installing
Special
Instructions
Torque: 30 Nm
(22 ft lb)
Torque: 6 to 10 Nm
(4 to 7 ft lb)
Replace
Torque: 24 Nm
(17 ft lb)
Coat sealing
surface with
original VW D 3
sealing compound
Torque: 25 Nm
(18 ft lb)
Torque: 25 Nm
(18 ft lb)
Position correctly magnet faces
down
Remove transmission before
removing
34 - 11
34
944
Note When:
No.
Description
18
Transmission case
34 - 12
Qty.
1
Removing
Installing
Special
Instructions
If transmission case
has to be replaced
and deviation
"r" is not on ring
gear, check location
of drive pinion
before removing
gear carrier
(actual distance)
Printed in Germany
944
34
Note
The differential need not be removed for jobs on the
gear carrier.
If the transmission case or tapered roller bearing for
the drive pinion has to be replaced and deviation "r"
is not given on the ring gear, measure actual
location
of drive pinion befare removing the gear carrier.
Installing
Note
It is recommended to install input shaft seal after
installation of gear set (danger of damaging).
1. Give gear carrier/transmission case sealing
surface
a thin coat of original VW D 3 sealing
compound.
Slide Special Tool 9178 on spline of input shaft
and install gear carrier with set of gears in
transmission case.
2. Drive in dowel sleeves and tighten mounting
bolts to specified torque.
3. Check by shifting through all gears with Special
Tool 9155.
Printed in Germany
34 - 13
34
34 - 14
944
Blank Page
944
Printed in Germany
34
34 - 15
34
944
Note When:
Special
Instructions
No.
Description
Qty.
End cover
Bolt 10 x 22 *
Washer
Bolt 8 x 45
Washer
Rear cover
Gasket
10
11
Synchromesh ring
12
Dowel sleeve
13
Circlip
14
Slide on sliding
sleeve with short
collar facing
gear
15
Only available
with selector rod
for 5th gear
16
Needle bearing
17
Stop bolt
18
Seal
Removing
Installing
Insert a large
screwdriver into
center of rubber
cover and pry out
Replace
Torque: 70 Nm
(51 ft lb)
Torque: 25 Nm
(18 ft lb)
Heat to about
120 C (250 F)
and drive on
Torque: 30 Nm
(22 ft lb)
0.2 mm thick,
replace
944
34
Note When:
No.
Description
Qty.
19
Bolt 10 x 22 *
20
Washer
21
5th gear
Heat to about
120 C (250 F)
and install
22
Adjusting screw
Note thickness
If necessary,
determine new
thickness
23
Dowel sleeve
24
Dowel sleeve
25
26
Insert in selector
rod with a linie
grease
27
Adjust operating
lever and torque
bolt to 35 Nm
(25 h tb)
28
Operating lever
Adjust before
installing shafts
29
Input shaft
30
31
32
Drive pinion
33
Dowel sleeve
34
Gear carrier
Removing
Installing
Special
Instructions
Torque: 70 Nm
(51 ft lb)
34 - 17
34
944
34 - 18
Printed in Germany
944
34
Printed in Germany
34 - 19
34
944
16. Drive out dowel sleeve for 3rd and 4th gear
selector fork, while holding with a hammer.
34 - 20
Printed in Germany
944
34
Assembling
1. Position lock pin in bore correctly.
17. Pull out selector rod for 3rd and 4th gears
(selector fork remains in sliding sleeve).
Do not loose small lock pin!
18. Unscrew bolt for operating lever.
19. Pull drive pinion and input shaft forward
slightly. Remove input shaft with 3rd and
4th gear selector fork.
N o t e: For transmissions with reverse gear synchronization disconnect spring clamp for reverse
gear on pinion shaft end and turn aside.
34 - 21
34
944
Note
Press roller bearing inner race off of input shaft to
make installation easier.
34 - 22
Printed in Germany
944
34
11. Lock dog for 1st and 2nd gear selector rod on
selector rod with a pin, while holding with a
hammer.
Distance "a"
(mm)
8.35 . . . 8.64
8.65 . . . 8.94
8.95 . . . 9.24
9.25 . . . 9.54
9.55 . . . 9.84
Shim
Thickness (mm)
Part Number
1.1
1.4
1.7
2.0
2.3
Printed in Germany
34 - 23
34
944
Thickness (mm)
N 900.606.01
N 900.606.02
N 900.606.03
1.35
1.40
1.45
34 - 24
944
34
Printed in Germany
34 - 25
34
34 - 26
944
Blank Page
944
Printed in Germany
34
34 - 27
34
944
Note When:
No.
Description
Qty.
Baffle plate
Circlip
Ball bearing
Cylindrical pin
Magnet
Cover
Removing
Installing
Press in with
30-205
Special
Instructions
Disassembling
34 - 28
Printed in Germany
944
34
Assembling
1. Press in hall bearing against stop with a
suitable pressing tool (e. g. 30-205).
Printed in Germany
34 - 29
34
34 - 30
944
Blank Page
944
34
TOOLS
No.
Description
Special Tool
Pressing tool
VW 472
Pressing tool
VW 473
Pressing tool
P 254 b
Printed in Germany
Remarks
34 - 31
34
34 - 32
944
944
34
Note When:
No.
Description
Qty.
Removing
Installing
Only available as
complete spare
part
Torque: 30 Nm
Replace
10
11
Adjust operating
lever and torque
bolt to 35 Nm
12
Adjust
13
14
15
16
17
18
19
20
Special
Instructions
Torque: 30 Nm
Torque: 24 Nm
Since Aug.
1984 bolt
with collar,
spacer
omitted
Connect single
angled end in
recess of synchromesh ring. Turn
double angled
end to left and
eonnect in end
bracket through
opening.
34 - 33
34
944
Note When:
Description
21*
Synchromesh ring
22
Reverse gear
23
Cylinder roller
bearing, outer
race
Press out
with 254 b
Press in to
correct position
with 254 b
24
Tapered roller
bearing, outer
race
Press out
suitable
pipe section
(e.g. VW 473)
Press in with
VW 472
25
Shim S4
Determine new
thickness if
necessary
26
End plate
Qty.
Special
Instructions
No.
Removing
Installing
Check for wear
If replaced,
determine new
thickness for
shim S4
34 - 34
944
34
Assembling
1. Press in cylindrical roller bearing outer race
to
correct position with P 254 b.
Pressed depth a = 8.5 to 9.0 mm.
New Installed
Distance
Wear
Limit
Reverse gear
0.75 - 2.3 mm
0.2mm
34 - 35
34
944
N o t e:
Operating lever has been adjusted correctly when it
is centered exactly above bushing for reverse gear
lock.
34 - 36
Printed in Germany
944
34
Thickness (mm)
0.24
0.27
0.30
0.33
0.36
0.39
0.42
0.45
0.69
0.93
1.17
1.4
= 119.10 mm
= 119.35 mm
Difference
0.25 mm
= 0.95 mm
+ difference
= 0.25 mm
New shim S4
= 1 .20 mm
34 - 37
34
34 - 38
944
Blank Page
944
34
TOOLS
No.
Description
Special Tool
Remarks
Internal puller 46 - 56 mm
US 1037
Mandrel
VW 295
Mandrel
VW 30 - 21
Slide hammer
VW 171
Spindle
US 1039
Thrust pad
VW 2050
Threaded sleeve
VW 771/15
Puller
VW 681
Intenal puller 30 - 37 mm
US 1108
10
Thrust pad
VW 511
11
Thrust pad
VW 30 - 205
12
Mandrel
VW 2062
Printed in Germany
34 - 39
34
944
944
34
Note When:
No.
Description
Qty.
Removing
Installing
Plug
Torque: 25 Nm
Seal
Replace, give a
light coat of oil
Clamping sleeve
Magnet
Seal
Threaded sleeve
Torque: 30 Nm
Gasket
Replace
Spring
10
Bushing
11
12
Cap
Pult off
13
Deflector
Engage retainer
in pipe of vent.
14
Seal
Replace; pack
space between
sealing tips with
multi-purpose
grease.
Special
Instructions
Page 34 - 43
Clean
Pult out with
VW 681
Drive in to stop
with VW 2062.
Pack space betw.
sealing tips with
multi-purpose
grease.
Torque: 30 Nm
34 - 41
34
944
Note When:
No. Description
Qty.
15
Seal
16
Removing
Installing
Drive in to stop
with VW 2062.
Pack space betw.
sealing lips with
multi-purpose
grease.
Seal
17
Press in with
VW 30-205
18
Shim S2
Determine new
thickness if
necessary
19
Shim S1
20
21
22
34 - 42
Needle bearing
Needle bearing
Special
Instructions
Drive in with
VW511 and
VW 295
Determine new
thickness if
necessary
Do not mix up
with needle
bearing no. 23.
Drive in flush
with VW 30-21.
Do not mix up
with needle
bearing no. 21.
Drive in to stop
with VW 30-21.
Printed in Germany
944
34
Note When:
No. Description
Qty.
Removing
Installing
23
When replacing,
measure installed
position (actual
distance) of drive
pinion befare
removing. Drive
out with VW 2050
and VW 771.
24
Shim S3
Determine new
thickness if
necessary
25
Dowel sleeve
26
Dowel sleeve
27
Transmission case
Special
Instructions
When replacing,
measure installed
position (actual
distance) of drive
pinion befare
disassembling.
Note
The seal (No. 3) and its groove in the cover have been omitted since June, 1984.
Sealing is now accomplished with Loctite No. 573 or 574.
34 - 43
34
944
Disassembling
1. Pull out seal for flange shaft with Special Tool
VW 681.
34 - 44
Printed in Germany
944
34
Assembling
Note
Note
Heat case for removal of outer race, since tapered
roller bearing outer race has a tight press-fit in the
case.
7. Pult out outer race for smalt tapered roller
bearing. Use a 46 to 56 mm internal claw puller
and spindle for this step.
Printed in Germany
34 - 45
34
944
Note
Do not mix up needle bearings for input shaft,
since they differ in outside diameter and number
af needles.
34 - 46
Printed in Germany
944
34
Note
It is recommended to install the seals for flange
shafts only after installation of the differential
to avoid damage.
7. Drive in seal for selector shaft against stop with
a suitable mandrel (e. g. VW 423).
Printed in Germany
34 - 47
35
M a n u a l T r a n s m i s s i o n / G e a r s, S h a f t s
944
35 - 00
Blank Page
944
35
TOOLS
No.
Description
Special Tool
Circlip pliers
VW 161 a
Press plate
VW 401
Pipe
VW 519
Separator
US 1103
Printed in Germany
Remarks
Standard
e. g. Kukko 15 - 17 Gr. 1
35 - 1
35
35 - 2
944
Printed in Germany
944
35
Note When:
No.
Description
Qty.
Circlip
2
3
4
Thrust ring *
Fourth gear
Needle bearing
1
1
1
Synchromesh ring
for 4th gear
Circlip
Synchronizer with
sliding sleeve for
3rd and 4th gears
7a
7b
7c
7d
8
Sliding sleeve
Synchonizer
Spring
Lock
Synchromesh ring
for 3rd gear
1
1
2
3
1
Third gear
10
Needle bearing
11
Circlip
12
Inner race
13
Input shaft
Removing
Installing
Special
Instructions
Determine new
thickness
Adjust axial play
Lubricate with
gear lube
Spray molybdenum on friction
surface. Check
for wear.
Determine new
thickness
Position correctly
Check axial play
Position correctly
Spray molybdenum on friction
surface. Check
for wear.
Check axial play
betw. 2nd and
3rd gears
Lubricate with
gear tube
Measure and install only after
installing input
shaft and inner
race.
Install only after
installing input
shaft
* Since September, 1983 the thrust ring (No. 2) has been omitted. The circlip (No. 1) and
recess in the input shaft were also changed.
Old and new parts or vice versa may not be installed with each other for repairs.
Adjusting the axial play on the fourth gear has been omitted.
35 - 3
35
944
Assembling
35 - 4
944
35
Circlips available:
Note
Groove in synchronizer body or wide collar of
hub faces 4th gear.
Part Number
Thickness (mm)
1.50
1.56
1.62
Printed in Germany
35 - 5
35
944
Circlips available:
Part Number
Thickness (mm)
1.65
1.70
1.75
35 - 6
Clearance "a"
I New Distance
(mm)
Wear Limit
(mm)
1.0 to 1.7
1.0 to 1.9
0.5
0.5
Printed in Germany
944
35
TOOLS
No.
Description
Special Tool
Support rail
VW 457
Pipe
VW 519
Thrust pad
VW 401
Standard
Separator
US 1103
e. g. Kukko 15 - 17 Gr. 1
Thrust pad
VW 454
Printed in Germany
Remarks
35 - 7
35
35 - 8
944
Printed in Germany
944
35
Note When:
No.
Description
Qty.
Removing
Installing
If necessary,
replace both bearings
together. Use same
make
Tapered roller
bearing
1st gear
Needle bearing
Synchronizer ring
for 1st gear
Angle 110.
Identification: each
3 x 1 tooth missing.
Friction surfaces
coated with
molybdenum and
spiral groove. Check
for wear
Circlip
Determine new
thickness
Synchronizer with
sliding sleeve for 1st
and 2nd gears
6a
Sliding sleeve
6b
Synchronizer body
6c
Spring
6d
Lock
Synchronizer ring
for 2nd gear
2nd gear
Needle bearing
Lubricate with
gear lube
10
Circlip
Determine new
thickness
Printed in Germany
Special
Instructions
Position correctly
35 - 9
35
944
Note When:
Description
11
3rd gear *
12
Circlip *
Thickness always
2.4 mm
13
Circlip *
Determine new
thickness
14
4th gear *
15
Tapered roller
bearing
16
Pinion shaft *
Qty.
Special
Instructions
No.
Removing
Installing
If necessary. replace
both together.
Use same make.
Check for wear.
Paired with ring gear.
Adjust pinion/ring
gear after replacing
parts.
* Beginning with 1983 models the 4th gear was changed from press-fit to spline-fit.
This change also affected 3rd gear, pinion shaft and circlips.
35 - 10
944
35
Disassembling
1. Press off inner race of tapered roller bearing
with 1st gear. Use Special Tool VW 457.
Printed in Germany
35 - 11
35
944
Assembling
1. Heat inner race for tapered roller bearing to
about 120 C (250 F) and press on.
A - Separator
35 - 12
Printed in Germany
944
Note
35
Circlips available:
Part Number
Thickness (mm)
2.24
2.26
2.28
2.30
2.32
2.34
2.36
2.38
2.40
Note
Clean gear and shaft with a greaseless cleaning
solution to remove all oil and grease, and heat
gear on a hot plate to approx. 120 C (250 F).
Note
Perform work very conscientiously, since otherwise
service life of tapered roller bearings could be
impaired.
Printed in Germany
35 - 13
35
944
Note
Coat molybdenum coated synchromesh rings with
an approved transmission oil.
Circlips available:
Part Number
Thickness (mm)
1.65
1.70
1.75
35 - 14
Printed in Germany
944
35
Circlips available:
Part Number
Thickness (mm)
1.50
1.55
1.60
Printed in Germany
35 - 15
35
944
Clearance "a"
I New Distance
(mm)
Wear limit
(mm)
1.0 to 1.7
0.5
35 - 16
Printed in Germany
944
Automatic Transmission
37
Printed in Germany
37 - 01
37
Automatic Transmission
944
TRANSMISSION IDENTIFICATION
944
37
Code Letters
installed in
087 M
RH
087 M
RCA
087 M
RCD
087 M
RCE
087 N
RCB
087 N
RCF
Technical Data
(Type 087 M and 087 N)
37 - 02a
37
37 - 02b
944
Blank Page
944
37
TECHNICAL DATA
Internal code
087 M
(087 N)
Number of gears
Ratios
Driving position 1
Driving position 2
Driving position D
Driving position R
Type 087 M
and N
Code letter
RCA, RCB,
RCD, RCE, RCF
i = 2.7143
i = 1.5000
i = 1.0000
i = 2.4286
Clutch
Converter ratio
2.08 (2.5)
Converter code
Stall speed
Final drive
Hypoid/ring gear
Hypoid displacement
44 mm
12/37 (11/38)
Type 087 M
Code letter
RH
i = 2.5517
i = 1.4483
i = 1.0000
i = 2.4615
(K)
Filling Capacities
Final drive
Automatic transmission
Technical Data
(Type 087 M and 087 N)
37 - 03
37
Automatic Transmission
944
Gear
1st
Gear
1st
Gear
2nd
Gear
3rd
Gear
Reverse
Gear
"1"
"2" + "D"
"2" + "D"
"D"
"R"
Forward clutch
closed
closed
closed
closed
open
D + R clutch
open
open
open
closed
closed
applied
released
released
released
applied
released
released
applied
released
released
One-way clutch
no power
transmission
holds
no power
transmission
no power
transmission
no power
transmission
37 - 04
944
Automatic Transmission
37
Printed in Germany
37 - 05
37
37 - 06
944
Blank Page
944
37
Description
Threads
Material
Torque Value
Nm (ft lb)
Plug
M 10 x 1
5.6
15
(11)
Coupling
M 24 x 1.5
9SMn 28 K
80
(58)
Bolt
M6
8.8
7
(5)
Bolt
M 10
8.8
42
(30)
Automatic transmission to
final drive
Nut
M 8 x 1.25
12.9
29
(21)
Intermediate plate to
transmission case
Bolt
M 5 x 0.8
5.8
3.5
(2.5)
Bolt
M6x1
8.8
7.0
(5)
Bolt
M 4 x 0.7
5.8
1.4
(1)
Nut
M 12 x 1.5
8.8
19.6
(14)
Bolt
M 8 x 1.25
8.8
20.5
(15)
Bolt
M 5 x 0.8
5.8
3.5
(2.5)
Bolt
M6x1
8.8
3.5
(2.5)
Bolt
M 5 x 0.8
5.8
3.5
(2.5)
Screw
M 5 x 0.8
5.8
3.5
(2.5)
Screw
M 5 x 0.8
8.8
3.5
(2.5)
Bolt
M6x1
5.8
3.5
(2.5)
37 - 07
37
944
Location
Description
Threads
Material
Torque Value
Nm (ft lb)
Nut
M 16 x 1.5
9SMn 28 K
20.5
(15)
Nut
M 8 x 1.25
9SMn 28 K
17
(12)
Bolt
M 8 x 1.25
8.8
20.5
(15)
Nut
M 10 x 1
9SMn 28 K
18
(13)
Bolt
M 8 x 1.25
8.8
9
(7)
Governor shaft to
governor housing
Screw
M 5 x 0.8
5.8
3.5
(2.5)
Flanged shaft to
differential
Bolt
M 8 x 1.25
8.8
25
(18)
Lockplate to adjusting
ring
Bolt
M6x1
8.8
8
(6)
Bolt
M 10 x1.5
10.9
42
(30)
Bolt
M 8 x 1.25
10.9
25
(18)
Ring gear to
differential
Bolt
M 10 x 1
12.9
78 - 93
(56 - 67)
Plug
M 24 x 1.5
UO-St36-2
20
(14)
Adapter
M 16 x 1.5
9SMn 28 K
80
(58)
Bolt
M8
12.9
40
(29)
37-08
Printed in Germany
944
37
Location
Description
Threads
Material
Torque Value
Nm (ft lb)
Coupling nut
M 16
5.8
30
(22)
Line to transmission
outlet
Hollow bolt
M 12
6.8
22.5
(16)
Line to transmission
inlet
Coupling nut
M 16
5.8
30
(22)
Hollow bolt
M 14
6.8
22.5
(16)
Coupling nut
M 16
5.8
30
(22)
Bolt
M6
8.8
5
(3.6)
Clamp
3
(2.2)
Lines to camshaft
housing
Bolt
M6
8.8
5
(3.6)
Adapter to radiator
Adapter
M 14
9SMn 28 K
30
(22)
Bolt
M 10 x 22
8.8
42
(30)
Bolt
M 6 x 15
8.8
7
(5)
Coupling bolt
M 24
9SMn 28 K
80
(58)
37 - 09
37
37 - 010
Automatic Transmission
944
Blank Page
944
37
Automatic Transmission
Location
Description
Threads
Material
Torque Value
Nm (ft lb)
Nut
M6
9
(7)
locking element to
shift base
Bolt
M6
8.8
8.2
(6)
Bolt
M6
8.8
8.2
{6)
Bracket to transmission
Bolt
M8
8.8
21
(15)
Cable to console
Coupling nut
M8
9SMn 28 K
8
(6)
Cable to bracket
Coupling nut
M8
9SMn 28 K
8
(6)
Nut
M5
5
(3.6)
37 - 011
37
37 - 012
Automatic Transmission
944
Blank Page
944
37
Automatic Transmission
Location
Description
Threads
Material
Torque Value
Nm (ft lb)
Nut
M8
04
5
(3.6)
Nut
M 10
17 H - 2
20
(15)
Hose damp
M4
3
(2.2)
Lock nut
M6
9
(7)
Accelerator pedal to
floor prate
Nut
M6
5
(3.6)
37 - 013
37
37 - 0
944
Blank Page
944
37
37 - 1
37
944
Note When:
No.
Description
Qty.
Lockplate
Ball socket
Washer
Nut
Dust cover
Mounting tube
Washer
Rubber washer
Sleeve
10
Rubber washer
11
Washer
12
Bolt
13
Selector grip
14
Spring
15
Push button
16
Sleeve
17
Cover
18
Bulb holder
19
Screw
37 - 2
Removing
Installing
Special
Instructions
Torque:
8 Nm (6 ft Ib)
Squeeze retaining
tabs on sides and
remove
Printed in Germany
944
37
Note When:
No.
Description
20
Contact plate
Installation mark
must align with
contact. Engine must
start only in position
"N" or "P", Coat
contact surface with
Molykote paste.
21
Bolt
Torque:
8.2 Nm (6 ft lb)
22
Small washer
23
Large washer
24
Strip guide
25
Lock washer
26
Rubber washer
27
Shift mechanism
28
Qty.
Removing
Installing
Do not bend.
Special
Instructions
37 - 3
37
944
37 - 4
Printed in Germany
944
37
Installing
1. Slide rubber grommet (see position 28 B in
layout
drawing) on to cable sleeve and coat front dust
cover with an assembly paste (e. g. rubber
lubricant).
2. Mount wire, pulled back during removal, on
cable
and pull cable forward through insulation sheet
carefully.
A - Rubber washer
37 - 5
37
944
Note:
Use a rubber grommet in opening of suspension
console to reduce the noise level.
37 - 6
Printed in Germany
944
37
Note:
Use lockpin to prevent ball socket from popping out.
Checking Adjustment
Place selector lever in "N", Run engine at fast idle
speed.
Pull up parking brake lever and brake car with brake
pedal for following tests.
1. Place selector lever in "R", Power transmission
must be indicated by drop in engine speed.
2. Place selector lever in "P". Reverse gear
disengages as indicated by rise in engine
speed.
37 - 7
37
944
2.
Note:
A lockpin prevents the ball socket from popping
out.
944
37
Note:
Press insulation sheet away from body with a
putty knife to avoid damaging sheet.
Installing
5. Mount cable correctly on transmission, cam
plate and accelerator pedal intermediate lever.
Note:
Cable must not be bent excessively.
Printed in Germany
37 - 8b
37
37 - 8c
944
Blank Page
944
37
Installing
Note:
37 - 9
37
944
Printed in Germany
944
37
Basic Setting
1.
Up to Mod. '85
37 - 11
37
944
6.
7.
8.
Note
It is very essential that the
control pressure (accelerator
side) cable be without tension, since
the throttle switch (idle contact)
will already be operated in a 1
throttle range.
37 - 12
Printed in Germany
944
9.
10.
1 = Basic position
2 = Prestress position
3 = Full throttle position
4 = Kickdown start
5 = Kickdown end
6 = Final stop
A = 0...2.5 mm
B = 10 mm
37
Kickdown Test
1.
37 - 12a
37
2.
3.
944
Note
If lever is more than 2.5 mm away
from final stop, the long cable
sleeve on the holder must be
readjusted in the area of the cam
plate.
37 - 12 b
Printed in Germany
944
37
Checking Function
The cause of damage or defect can be pinpointed
with help of the troubleshooting card (page 37-17)
and the following tests before repairing an
automatic transmission.
A - General Test
B - Automatic Transmission and Final Drive Oil
level Test
C - Stall Speed Test
D - Road Test
E - Pressure Test
Important!
All jobs, which require the engine to be running,
should only be performed with the selector lever in
"N" or "P" and the parking brake applied.
Important!
A - General Test
Important!
B - Automatic Transmission and
Final Drive Oil level Test
37 - 13
37
944
Forward clutch
slips.
1st gear one-way
clutch slips.
One-way clutch in
torque converter
defective
Important!
Note:
Stall speed will be reduced by about 125 rpm for
each 1,000 meters (3,300 f t) above sea level.
The stall speed could also drop slightly with
high outside temperatures.
37 - 14
Printed in Germany
944
37
D - Road test
Road test car (only when there is
no obvious transmission damage).
It is important to drive the car
in as many driving conditions as
possible, and in all the driving
ranges of the automatic transmission. Careful observation is
a must. Pay particular attention
to shifting points for upshifts and
downshifts, as well as the kickdown
shift points with reference to
speed and gear transitions.
S h i f t p o i n t s in KM/H 944/924 S
Transmission Version
Shifts
Full Throttle*
Kickdown*
Transmission type
087 M
Code letter
RH
1-2
2-3
3-2
2-1
40 - 56
96 - 120
68 - 94
28 - 31
89 - 92
155 - 156
148 - 150
81 - 83
Transmission Version
Shifts
Full Throttle*
Kickdown*
Transmission type
087 M
Code letter
RCA, RCD, RCE
1-2
2-3
3-2
2-1
40 - 55
96 - 120
69 - 95
28 - 32
83 - 88
149 - 152
142 - 146
76 - 81
Transmission Version
Shifts
Full Throttle*
Kickdown*
Transmission type
087 N
Code letter
RCB, RCF
1-2
2-3
3-2
2-1
35 - 48
84 - 105
60 - 83
25 - 28
73 - 77
130 - 133
124 - 128
67 - 71
* Note that during testing the speedometer can deviate from the specified
values within permissible tolerances.
Cheeking Operation
(Type 087 M and 087 N)
37 - 15
37
944
Accelerator Pedal
Position
Main Pressure
in bar
Testing Conditions
Idle
(no acceleration)
2.90...3.00
Full throttle
7.3...7.40
9.5 +- 0.3
Car stopped
Full throttle
more than 20
At stall speed
* Road speed faster than 140 km/h for Europe models (transmissions RCD and RCE) since December, 1983.
This test should be performed on a dynamometer whenever possible. For the pressure test in idle, accelerate the car to specified read speed, take foot off of the accelerator pedal and read the pressure.
37 - 16
944
37
It is not possible to adjust the main pressure. There could be the following causes for deviation from
the specified values.
Cause
Correction
37 - 16a
37
37-17a
Troubleshooting chart
944
944
Troubleshooting chart
37
37 - 17b
37
37 - 18
944
Blank Page
944
37
37 - 19
37
944
Note:
Cables are locked in ball sockets to prevent popping
out.
Note:
Suspend drive shafts from car with pieces of wire in
horizontal position to prevent damaging dust covers.
Printed in Germany
944
37
37 - 21
37
37 - 22
944
Blank Page
944
37
37 - 23
38
38 - 0
944
Blank Page
944
38
TOOLS
No.
Description
Filler
Special Tool
Remarks
Commercial item,
e. g. Dresser-Wayne Model 3009
38 - 1
38
944
1.
ATF liquid
(ATF-Dexron II D) is no longer red
and transparent, but brown and
becomes completely black after short
operation.
Oil volume:
New filling with ATF cooler =
approx. 6.5 liters
Oil change:
approx. 2.8 liters
Oil grade:
ATF-Dexron II D
Tightening torques:
Oil filler tube to oil sump =
80 Nm
38 - 2
944
38
Note:
The specified ATF level is extremely
important for perfect operation of the
automatic transmission.
1. Car must be on level surface.
Note:
Clean upper section of tank and cover prior
to adding ATF, to prevent dirt from entering
filling tank.
38 - 2a
38
944
38 - 2 b
Printed in Germany
944
38
Note:
Note:
A = Adapter
Part No. 087.409.057 B
38 - 2c
38
38 - 2d
944
Blank Page
944
38
TOOLS
No.
Description
Special Tool
Holder
VW 351
Hole plate
Remarks
Made locally
(10 mm thick)
38 - 3
38
38 - 4
944
Printed in Germany
944
38
Note When:
No.
Description
Qty.
Removing
Installing
Torque converter
Nut
Torque:
29 Nm (22 ft lb)
Spring washer
Replace. if necessary
Automatic transmission
Gasket
Replace
Shim
Different thicknesses.
adjust axial play
Replace
Seal
Final drive
10
Turbine shaft
Special
Instructions
Check length;
check piston rings
38 - 5
38
944
2.
3.
38 - 6
A - Wire ring
Printed in Germany
944
38
Installing
Drive in seal carefully with Special Tool 30 - 24.
Sealing lip faces out.
Removing
Drive out seal with a standard internal-claw puller
and an old oil pump shaft. A suitable round rod
could also be used instead of pump shaft.
A - Pump shaft
B - Internal-claw puller
C - identification (groove)
38 - 7
38
944
Removing
Installing
Note:
Extreme care is required for installation of seal.
The material is very soft and consequently easy
to damage. Never let seal come in contact with
gasoline or cleaning solutions.
38 - 8
Printed in Germany
944
38
Measuring Points:
Procedures
1. Measure distance "a" on final drive.
Place straight-edge on case and measure
distance to bushing for seals.
a - Final drive:
case sealing surface to bushing for seals.
b - Automatic transmission:
bearing collar for shim to intermediate
plate with gasket.
1 - Final drive
2 - Automatic transmission
3 - Ring gear
4 - Gaskets
5 - Intermediate plate
6 - Drive pinion
7 - Shim
Example:
Straight-edge to bushing
Straight-edge to sealing surface
Case distance "a" =
18.7 mm
8.0 mm
10.7 mm
========
38 - 9
38
944
Example:
Distance "a"
Distance "b"
Distance "x"
10.7 mm
9.2 mm
1.5 mm
=======
Shim (mm)
0.23 . . . 0.84
0.85 . . . 1.24
1.25 . . . 1.64
1.65 . . . 2.04
2.05 . . . 2.44
none
1 x 0.4
2 x 0.4
1 x 1.2
1 x 0.4
1 x 1.2
2 x 0.4
1 x 1.2
2 x 1.2
1 x 0.4
2 x 1.2
2 x 0.4
2 x 1.2
2.45 . . . 2.84
2.85 . . . 3.24
3.25 . . . 3.64
3.65 . . . 3.88
Example:
Straight-edge to gasket
Straight-edge to bearing collar
Distance "b" =
19.2 mm
- 10.0 mm
9.2 mm
=======
38 - 10
Printed in Germany
944
38
38 - 11
38
944
Note When:
No.
Description
Qty.
Removing
Installing
Screw
Torque:
3.5 Nm
Intermediate plate
Check, adjusting if
necessary, axial play
of automatic transmission/final drive
af ter installation
Gasket
Replace
Thrust washer
Circlip
Position correctly,
push in with end of
hammer handle if
necessary
Holding wedge
Opening must be
opposite holding
wedge. Automatic
transmission is
assembled correctly
when groove for
circlip is accessible.
One-way clutch
10
Reverse planetary
gear set
11
Thrust washer
12
Check identification.
Place in ATF 15 min.
before installing.
13
38 - 12
944
38
Note When:
No.
Description
Qty.
14
Corrugated washer *
15
Thrust washer
(steel)
16
Drive shell
17
Sun gear
18
Forward planetary
gear set
19
20
Forward clutch
21
Bearing ring
22
Bearing cage
23
Bearing ring
24
Thrust washer
25
26
Nut
Torque:
20 Nm
27
Adjusting screw
28
Support
29
Circlip
Removing
Installing
38 - 13
38
944
Note When:
No.
Description
Qty.
30
31
Spring
32
Brake band
(2nd gear brake)
Adjust
33
Bolt
M 6 x 35
Torque:
7.0 Nm
34
Lock washer **
Replace, if necessary
35
36
Shell *
Check length,
position correctly
37
38
39
Transmission case
Removing
Installing
Remove before
removing brake
band. Remove by
applying light
taps from rubber
hammer on cover
surface.
38 - 14
944
38
Disassembling
Assembling
38 - 15
38
944
Note:
Shell length distance "a" = 94.9 mm.
5. Install piston and end cover for 2nd gear brake
and mount circlip. Press down piston and end
cover with a suitable tool.
38 - 16
Printed in Germany
944
38
38 - 17
38
944
Note:
Only adjust brake band with transmission
positioned
horizontally, since otherwise brake band would
jam.
Parts have been assembled correctly, if groove
for circlip is accessible.
38 - 18
Printed in Germany
944
38
MODIFICATIONS
Corrugated washer for first gear
brake dropped.
Note
From March 1983, corrugated washer
(Item 14) has been dropped, length
of shell (Item 36) changed and
piston (Item 37) equipped with a
ball valve.
Wet piston with ATF and insert in
transmission case so that ball valve
of piston (arrow 2) is flush with
transmission case bore (arrow 1).
38 - 18 a
38
38 - 18b
944
Blank Page
944
38
Note When:
No.
Description
Qty.
Circlip
Ring gear
Removing
Installing
Special
Instructions
38 - 19
38
38 - 20
944
Blank Page
944
38
Note When:
No.
Description
Qty.
Removing
Installing
Roller
10
Position correctly
Spring
10
Circlip
Cage
Circlip
Outer race
Special
Instructions
38 - 21
38
944
Note:
Assembling
1. Install lower circlip.
38 - 22
Printed in Germany
944
38
Note When:
No.
Description
Qty.
Outer race
Removing
Installing
Insert into
outer race in
correct position
from below. Lock
by turning
38 - 22a
38
944
Assembly
1. Combine 10 segments in one ring.
38 - 22b
Printed in Germany
944
38
38 - 22c
38
38 - 22d
944
Blank Page
944
38
TOOLS
No.
Description
Special Tool
VW 387
Dial gauge
Remarks
Standard
38 - 23
38
38 - 24
944
Printed in Germany
944
38
Note When:
No.
Description
Qty.
Removing
Installing
Circlip
Pressure plate
Different thicknesses,
adjust axial play
Inner plate
Outer plate
Ring gear
Pressure plate
Circlip
Diaphragm spring
should already get
slight preload from
installed circlip;
replace diaphragm
spring if necessary
Diaphragm spring
Piston
10
Clutch drum
Measure position of
groove for circlip.
Check ball valve - in
direction of arrow =
tight, in opposite
direction of arrow =
open
38 - 25
38
944
Assembling
1. Measure location of groove for circlip. Distance
"a"
= 29.8 mm. There are different version, consequently only install a clutch drum with correct
distance "a".
38 - 26
Printed in Germany
944
38
TOOLS
No.
Description
Special Tool
Bridge
VW 460/3
Thrust pad
VW 433
Thrust plate
VW 402
Thrust plate
VW 401
Punch
VW 411
Drift
VW 295
Remarks
Standard tool
38 - 27
38
38 - 28
944
Printed in Germany
944
38
Note When:
No.
Description
Qty.
Removing
Installing
Different thicknesses.
adjust axial play
Circlip
Pressure plate
Inner plate
Outer plate
Circlip
Spring retainer
Spring
16
Spring retainer
Piston
10
Bushing
11
Clutch drum
Special
Instructions
Remove with
VW 460/3
38 - 29
38
944
Assembling
1. Check the ball valve for leakage (see page
38-29, Item 11).
944
38
Note:
Only install inner plates, the linings of which are
identified as shown in the picture.
38 - 31
38
38 - 32
944
Blank Page
944
38
38 - 33
38
944
Note When:
No. Description
Qty.
Removing
Installing
Torque:
1.4 Nm (1 ft lb)
Screw
Cover
Valve spring
Drive dog
Inner gear
Outer gear
10
Thrust washer
Remove after
removing piston rings
11
Body
Special
Instructions
38 - 34
Printed in Germany
944
38
38 - 35
38
944
Note When:
No. Description
Qty.
Removing
Installing
Bolt
Torque:
20.6 Nm (15 ft lb)
Lock washer
Replace if necessary
Oil sump
Gasket
Replace
Screw
Torque:
3.5 Nm (2.5 ft lb)
Spring washer
Cover
Gasket
10
Bolt
11
11
Spring washer
11
12
Valve body
13
14
Piston for
accumulator
38 - 36
Special
Instructions
Replace
Unscrew bolt shown
in drawing last
Torque:
3.5 Nm (2.5 ft lb)
Printed in Germany
944
38
Note:
The valve body can be removed from a
transmission
installed in the car.
Note:
Never run engine or have car towed when transmission oil sump has been removed or oil drained.
Installing
1. Connect manual valve (arrow A) and kickdown
valve (arrow B).
38 - 37
38
944
38 - 40
Printed in Germany
944
38
Note When:
No.
Description
Qty.
Removing
Installing
Torque:
3.5 Nm (2.5 ft lb)
Washer
Replace if necessary
19
Tighten uniformly to
torque of 3.5 Nm
(2.5 ft lb)
Washer
19
Replace if necessary
Transfer plate
Note marks
Separation prate
Note marks
Ball (6 mm dia.)
Note arrangement
10
Ball (3 mm dia.)
Note arrangement
11
Valve body
Note marks
Special
Instructions
38 - 41
38
944
3. Identification of separation
plate:
Transmission types RCA, RCB
and RCF
Arrow 1 = 2 notches
Arrow 2 = 3 notches
Arrow 3 = 1 notch
2. Identification of separation
plate:
Transmission type RH
Arrow l = 3 notches
Arrow 2 = 2 notches
38 - 42
4. Identification of separation
plate:
Transmission types RCD and RCE
Arrow 1 = 2 notches
Arrow 2 = 4 notches
Arrow 3 = 1 notch
944
38
Identification is by means of a
coding vane (arrow), screwed on to
the transfer plate.
Note
The coding vane must remain pointing
to valve body during repair.
38 - 43
38
38 - 44
944
Blank Page
944
38
Parts must be removed from a valve body to clean a very dirty valve body. These parts should be placed
in a special tray to guarantee re-installation in original position. Outside shape of tray matches that of
valve body to facilitate insertion of valves and springs.
Disassembling
Assembling
Note:
Note:
Coat all valves with ATF and check for free movement. Valves must slide down bores by their own
weight.
38 - 45
38
38 - 50
944
Blank Page
944
38
38 - 51
38
944
Note When:
No. Description
Qty. Removing
Installing
Manual valve
Screw
Torque:
3.5 Nm (2.5 ft lb)
Washer
Replace if necessary
End plate
Kickdown valve
Throttle pressure
valve spring
Throttle pressure
valve
Shift valve
1 - 2 spring
10
Shift valve 1 - 2
11
Screw
Torque:
3.5 Nm (2.5 ft lb)
12
Washer
Replace if necessary
13
End plate
14
Converter pressure
valve spring
15
Spring retainer
16
Converter pressure
valve
17
Shift valve
2 - 3 spring
18
Shift valve 2 - 3
19
3 - 2 kickdown
control valve spring
20
Spring retainer
21
3 - 2 kickdown
control valve
38 - 52
Special
Instructions
Printed in Germany
944
38
Note When:
No.
Description
22
Screw
Torque:
3.5 Nm (2.5 ft lb)
23
Washer
Replace if necessary
24
End plate
25
Control valve 3 - 2
26
Control valve 3 - 2
spring
27
Governor plug 2 - 3
28
Screw
Torque:
3.5 Nm (2.5 ft lb)
29
Washer
Replace if necessary
30
End plate
31
32
33
34
35
36
37
Sleeve
38
39
40
41
Sleeve
Qty.
Removing
Installing
Special
Instructions
38 - 53
38
944
Note When:
No.
Description
42
Throttle pressure
limiting valve
adjusting screw
43
Throttle pressure
limiting valve spring
44
Spring retainer
45
Throttle pressure
limiting valve
46
Governor plug 1 - 2
47
Body
38 - 54
Qty.
Removing
Installing
Special
Instructions
Note marks
Printed in Germany
944
38
38 - 54a
38
944
Note When:
No.
Description
Qty.
Removing
Manual valve
Screw
End plate
Kickdown valve
Throttle pressure
valve spring
Throttle pressure
valve
Shift valve
spring
1-2
Shift valve
1-2
10
Screw
11
End plate
12
Converter pressure
valve spring
13
Spring retainer
14
Converter pressure
valve
15
Step pressure
valve spring
16
Step pressure
valve
17
Shift valve
spring
38 - 54 b
Installing
Torque: 3.5 Nm
Same size as
spring for shift
valve 2-3, but do
not mix up
Torque: 3.5 Nm
2-3
Same size as
spring for shift
valve 1-2, but
do not mix up
Printed in Germany
944
38
Note When:
No.
Description
18
Shift valve
19
3 - 2 kick down
control valve
spring
20
Spring retainer
21
3 - 2 kickdown
control valve
22
Screw
23
End plate
24
Control valve
3-2
25
Control valve
3 - 2 spring
26
Governor plug
2-3
27
Screw
28
End plate
29
30
31
Main pressure
valve adjusting
screw
32
Main pressure
valve spring
33
Main pressure
valve
Qty.
Removing
Installing
2-3
Torque: 3-5 Nm
Torque: 3.5 Nm
38 - 54c
38
944
Note When:
No.
Description
34
Sleeve
35
Main pressure
limiting valve
adjusting screw
36
Main pressure
limiting valve
spring
37
Main pressure
limiting valve
38
Sleeve
39
Throttle pressure
limiting valve
adjusting screw
40
Throttle pressure
limiting valve
spring
41
Spring retainer
42
Throttle pressure
limiting valve
43
Governor plug
1-2
44
Body
38 - 54 d
Qty.
Removing
Installing
Note marks
Printed in Germany
944
38
Note When:
No. Description
Qty.
Removing
Installing
Cover
Seal
Return spring
Seal
Seal
Circlip
Modulator piston
Shim
Accumulator spring
10
Spring retainer
11
Piston rod
Special
Instructions
Replace
38 - 55
38
944
Note
Securing the piston rod to the
piston has been changed.
Previously: Circlip
Changed:
Riveted on to piston
with disk (arrow)
Distance "a"
D+R clutch with 134 mm
D+R clutch with 140 mm
38 - 56
61,9 +- 0,5 mm
52,4 +- 0,5 mm
944
38
38 - 57
38
944
Note When:
No.
Description
Qty.
Removing
Installing
Screw
Torque:
3.5 Nm (2.5 ft lb)
Washer
Replace if necessary
Thrust plate
Governor shaft
Can be replaced
separately
Transfer plate
Position correctly
Balance weight
Circlip
Centrifugal weight
Pull rod
10
Spring retainer
11
Spring
12
Valve
13
Body
38 - 58
Special
Instructions
Printed in Germany
944
38
38 - 59
38
944
Note When:
No. Description
Qty.
Cap
Nut
Spacer
Lever
Circlip
Thrust washer
Nut
Washer
10
Shaft
11
Seal
12
Lock wacher
13
Nut
14
Washer
15
Stop washer
16
Ratchet
17
Lock washer
18
Engaging lever
19
Lock washer
20
Operating rod
21
Bolt
22
Washer
38 - 60
Removing
Installing
Special
Instructions
Torque:
20 Nm (14 ft lb)
Torque:
17 Nm (12 ft lb)
Position correctly
Torque:
20.5 Nm (15 ft lb)
Torque:
3.5 Nm (2.5 ft lb)
Printed in Germany
944
38
Note When:
No.
Description
Qty.
23
Lever
24
Seal
25
Bolt
Torque:
20.5 Nm (15 ft lb)
26
Lock washer
27
Spring
28
Bolt
29
Pawl
30
Spring
Position correctly
Removing
Installing
Special
Instructions
* Operating lever for kickdown valve is flat on stop surface A as from 1983 model.
Note:
New operating lever can also be installed in old transmission.
Old operating lever, however, may not be installed in
transmission with new kickdown valve.
38 - 61
39
39 - 0
Differential/Transaxle System
944
Blank Page
944
Printed in Germany
Differential/Transaxle System
39
39 - 1
39
Differential/Transaxle System
944
Note When:
No.
Description
Qty.
Threaded sleeve
Gasket
Spring
Sleeve
Bolt
Washer
Cover
Gasket
Selector shaft
assembly
10
Dowel sleeve
11
Bolt
12
12
Gear carrier
assembly
13
Bolt
14
Flange shaft
15
16
Cover
17
Differential
39 - 2
Removing
Installing
Special
Instructions
Torque: 30 Nm
(22 ft lb)
Torque: 6 to 10 Nm
(4 to 7 ft lb)
Replace
Torque: 24 Nm
(17 ft lb)
Coat sealing surface
with original VW
sealing compound
D3
Torque: 25 Nm
(18 ft lb)
Torque: 25 Nm
(18 ft lb)
Position correctly,
magnet faces
down
Remove gearbox
before removing
Printed in Germany
944
Differential/Transaxle System
39
Note When:
No.
Description
18
Case
Printed in Germany
Qty.
1
Removing
Installing
Special
Instructions
If transmission
case has to be replaced and
deviation "r" is
not given on ring
gear, check position
of pinion shaft prior
to removing the gear
carrier (actual
distance)
39 - 3
39
Differential/Transaxle System
944
Removing
Installing
Note
39 - 4
Printed in Germany
944
Differential/Transaxle System
39
TOOLS
No.
Description
Special Tool
Remarks
Puller
US 1078
Thrust pad
VW 295 a
Pipe
VW 40 - 21
Printed in Germany
39 - 5
39
39 - 6
Differential/Transaxle System
944
Printed in Germany
944
Differential/Transaxle System
39
Note When:
No.
Description
Qty.
Removing
Installing
Bolt
11
Loosen, then
tighten crosswise to 85 . . . 100
Nm (61 to 72 ft lb)
Ring gear
Dowel sleeve
Shaft
Small differential
gear
Thrust washer
Large differential
gear
10
11
Shim
Determine new
thickness
12
Differential
housing
Printed in Germany
Special
Instructions
Drive in flush
Drive in with a
suitable mandrel
Drive in carefully
to avoid damage
on thrust washers.
Lock with dowel
sleeve
39 - 7
39
Differential/Transaxle System
944
Printed in Germany
944
Differential/Transaxle System
39
Assembling
1. Heat inner races for small and large tapered
roller
bearings to about 100 C (210 F). Install on
differential and press on to correct position. Use
Special Tool VW 40 - 21.
A - Centering pins
4. Tighten ring gear with new bolts and tighten
bolts to specified torque crosswise.
2. Install differential gears. Install large differential
gears with correct shims. Install small differential
gears with 180 offset (hold thrust washer in
place with a little grease) and swing in. Align
thrust washers with shaft bore. drive in shaft
carefully and lock with a split pin.
ADJUSTING DIFFERENTIAL GEARS
1. Install large differential gears with thinnest
shims (0.5 mm).
2. Install small differential gears with thrust
washers and press in shaft.
Printed in Germany
39 - 9
39
Differential/Transaxle System
944
Shims available:
4. Adjust play to max. 0.10 mm by installing a
shim
of correct thickness.
Note
Part Number
Thickness (mm)
0.5
0.6
0.7
0.8
39 - 10
Printed in Germany
944
39
Tools
No.
Description
Special Tool
1
2
3
4
5
6
7
8
Universal gauge
Univ. dial gauge holder
Centering disk
Centering disk
Master gauge
Gauge plate
Sleeve
Dial gauge extension
9.3 mm
Gauge punger
Dial gauge
Adjustable lever
Dial gauge extension
Dial gauge
Adjusting device
Torque meter
VW
VW
VW
VW
VW
VW
VW
VW
9
10
11
12
13
14
15
385/1
387
385/2
385/3
385/30
385/17
521/8
385/15
VW 385/14
VW 388
VW 521/4
Remarks
39 - 11
39
Differential/Transaxle System
944
Service Sets
Standard Sets
Important!
39 - 12
944
Differential/Transaxle System
39
S1 = Shim
S2 = Shim
S3 = Shim
S4 = Shim
39 - 13
39
Differential/Transaxle System
944
Adjustment Survey
The pinion and ring gear only have to be adjusted when repairs on the final drive require the replacement
of parts having direct influence on the adjustment. Refer to the following table to avoid unnecessary
adjustments!
Replaced Part
Ring Gear
(S1 + S2)
Transmission case
Pinion
Deviation
Pinion
"Actual"
distance
X
Pinion
only shim
"S4"
X
X
Pinion/ring gear
39 - 14
Printed in Germany
944
Differential/Transaxle System
39
4. Mount gauges.
Set dial gauge (3 mm range) to 0 with 1 mm
preload. Dial gauge extension length approx.
30mm.
5. Move drive pinion up and down. Read play on
dial gauge and note the value. Do not turn drive
pinion during this step to avoid wrong readings.
Example: 1.30 mm.
6. Take off gear carrier again.
Pre-load
Measured value
= 1.30 mm (example)
Stot
1.60 mm
a = approx. 50 mm
Printed in Germany
39 - 15
39
944
39 - 16
944
39
S3 = e + r
e = Determined value
(max. dial gauge deflection)
r = Deviation (given on the ring gear in
1/100 mm or determined by measuring
the actual distance)
Example:
Value indicated
on the dial gauge "e"
Deviation value
given on the ring gear "r"
Shim thickness "S3"
0.46 mm
+ 0.18 mm
--------0.64 mm
39 - 16a
39
39 - 16b
Differential/Transaxle System
944
Blank Page
944
Differential/Transaxle System
39
Note
1.60 mm
- 0.64 mm
0.96 mm
Thickness (mm)
0.24
0.27
0.30
0.33
0.36
0.39
0.42
0.45
0.69
0.93
1.17
1.41
Note
Lubricate bearings with hypoid gear lube.
39 - 17
39
Differential/Transaxle System
944
39 - 18
Printed in Germany
944
39
Differential/Transaxle System
Note
Note
Example:
Measured value (example)
Pre-load (constant value)
Stot
Printed in Germany
1,42 mm
+ 0.50 mm
1.92 mm
39 - 19
39
Differential/Transaxle System
944
Adjusting Backlash
Example:
1st measurement
2nd measurement
3rd measurement
4th measurement
Sum
0.84 mm
0.85 mm
0.84 mm
0.83 mm
3.36 mm
a - 79 mm
Example:
Stot
Lift
Mean backlash
S2
1.92 mm
+ 0.15 mm
- 0.84 mm
1.23 mm
Printed in Germany
944
Differential/Transaxle System
Shims Available:
39
Part Number
Thickness (mm)
0.15
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.20
Note
Measurements must not deviate from each other
by
more than 0.05 mm.
1.92 mm
- 1.23 mm
0.69 mm
Shims Available:
Part Number
018 409 381
018 409 383
018 409 385
018 409 387
018 409 389
018 409 391
018 409 393
Printed in Germany
Thickness (mm)
0.15
0.20
0.25
0.50
0.80
1.00
1.50
39 - 21
39
39 - 50
Differential/Transaxle System
944
Blank Page
944
39
Printed in Germany
39 - 51
39
39 - 100
944
Blank Page
944
39
Location
Description
Threads
Material
Torque
Nm (ft lb)
Bolt
M 8 x 25
8.8
21
(15)
Bolt
M 10 x 46
12.9
80
(58)
Bolt
M 10 x 35
8.8
42
(30)
Bolt
M 12 x 80
10.9
85
(61)
Bolt
M 10 x 50
8.8
42
(30)
Bolt
M 8 x 11
12.9
40
(29)
Bolt
M 10 x 46
12.9
80
(58)
Damper to flywheel
Bolt
M 8 x 40
8.8
21
(15)
Bolt
M 10 x 25
8.8
42
(30)
Support to transmission
Bolt
M 10 x 30
8.8
42
(30)
Nut
M8
20
(14)
39 - 101
39
944
Location
Description
Threads
Material
Torque
Nm (ft lb)
Flanged shaft to
differential
Bolt
M 8 x 1.25
8.8
25
(18)
Bolt
M6x1
8.8
8
(6)
Bolt
M 10 x 1.5
10.9
42
(30)
Bolt
M 8 x 1.25
10.9
25
(18)
Bolt
M 10 x 1
12.9
78-93
(56 - 67)
Automatic transmission to
final drive
Nut
M 8 x 1.25
12.9
29
(21)
Bolt
M8
12.9
42
(30)
39 - 102
Printed in Germany
944
39
39 - 103
39
39 - 104
Differential/Transaxle System
944
Blank Page
944
39
TOOLS
No.
Description
Special Tool
Slide hammer
VW 771
Drift
VW 295
Driving mandrel
2056
Sleeve
30 - 21
Transmission support
VW 353
Separator
US 1103
Internal puller
US 1108
Internal puller
US 1137
Remarks
39 - 105
39
No.
Description
Special Tool
Spanner wrench
VW 544
10
VW 439
11
Mounting plate
12
Thrust plate
VW 402
13
Thrust plate
VW 401
14
Spacer
VW 545/2
15
Tube
VW 516
16
Thrust rings
VW 470
17
Sleeve
2055
18
Drive sleeve
VW 192 or
US 4450
19
Drive sleeve
VW 551
20
Thrust tube
VW 454
21
Thrust pad
VW 412
22
Driver
VW 195
23
Thrust pad
30 - 205
24
Thrust pad
VW 510
944
Remarks
Made locally
39 - 106
Printed in Germany
944
39
39 - 107
39
944
Note When:
No.
Description
Qty.
Removing
Installing
Torque:
25 Nm (18 ft lb)
Torque:
25 Nm (18 ft lb)
Bolt
Flanged shaft
Bolt
Flanged shaft
Bolt
Washer
Washer
Governor cover
Seal
10
Governor
11
Seal
12
Needle bearing
13
Bolt
11
Torque:
25 Nm (18 ft lb)
14
Lock washer
11
Replace if necessary
15
Cover
16
Seal
17
Seal
39 - 108
Special
Instructions
Torque:
9 Nm (7 ft lb)
Replace
Printed in Germany
944
39
Note When:
No. Description
Qty.
Removing
Installing
18
Bolt
Torque:
42 Nm (30 ft lb)
19
Lock washer
Replace if necessary
20
cover
21
Seal
22
Seal
23
Seal
24
Seal
25
Tapered roller
bearing outer race
26
Bolt
27
Washer
28
Lockplate
29
Adjusting ring
30
Seal
31
Seal
32
Tapered roller
bearing outer race
33
Adjusting ring
Special
Instructions
Torque:
8 Nm (6 ft lb)
39 - 109
39
944
Note When:
No.
Description
Qty.
34
Differential
35
Pinion
36
Sleeve
Press off
Heat to approx.
100 C/212 F and
press on
37
Tapered roller
bearing
Press off
Heat to approx.
100 C/212 F and
press on. Adjust if
replacing pinion
38
Shim
39
Tapered roller
bearing
40
Shim S 4
41
Case
42
43
Seal
Position correctly,
drive on with 2056
44
Adapter
Torque:
80 Nm (58 ft lb)
45
Seal
Replace
46
Adapter
Torque:
80 Nm (58 ft lb)
47
Seal
Replace
39 - 110
Removing
Installing
Special
Instructions
Determine thickness
Press off
Heat to approx.
100 C/212 F and
press on. Adjust if
replacing pinion
Determine thickness
Printed in Germany
944
39
Disassembling
Note:
If pinion/ring gear and bearings can be reused,
determine backlash and turning torque of pinion
before disassembling final drive, note these figures
and install them again as accurately as possible.
39 - 111
39
944
Assembling
1. Drive in needle bearing for governor against stop
4.
39 - 112
Printed in Germany
944
39
Disassembling
1. Remove torque converter seal.
Assembling
1. Press in outer race for tapered roller bearing.
39 - 113
39
944
39 - 114
Printed in Germany
944
Blank Page
39
39 - 115
39
944
39 - 116
Printed in Germany
944
39
Assembling
1. Heat large tape red roller bearing to approx.
100 C/212 F and install. Then press on tight.
2. Press off sleeve for seals.
A - US 1103
39 - 117
39
944
39 - 118
Printed in Germany
944
39
Modifications:
Removing and installing flat
governor
1 - Screw
2 - Retaining plate
3 - Drive
Disassemble speedometer drive.
1 - Flat governor
2 - Sealing ring (always renew)
3 - Governor cover
4 - Screw
Removing and installing speedometer
drive
1 - Lock
2 - Pinion
3 - Bearing
4 - Sealing ring (always renew)
Lift lock (1) of pinion (2) using
two screwdrivers. Remove pinion
from bearing (3).
39 - 118a
39
39 - 118b
944
Blank Page
944
39
TOOLS
No.
Description
Special Tool
Thrust plate
VW 402
Thrust pad
VW 412
Drive sleeve
40 - 21
Puller
US 1078
Adapter
VW 295 a
Remarks
39 - 119
39
39 - 120
944
Printed in Germany
944
39
Note When:
No. Description
Qty.
Removing
Installing
Tapered roller
bearing
Heat to approx.
100 C/212 F. Then
press on tight. Adjust
ring gear if replacing
Tapered roller
bearing
Heat to approx.
100 C/212 F. Then
press on tight. Adjust
ring gear if replacing
Bolt
10
Torque 78 . . . 93 Nm
(56 . . . 67 ft lb)
Ring gear
Cover
Thrust washer
Large differential
gear
Connector, flanged
shaft
Shaft
10
Small differential
gear
11
Thrust washer
12
Connector, flanged
shaft
13
Large differential
gear
14
Thrust washer
15
Housing
Special
Instructions
39 - 121
39
944
Assembling
Note:
Clean mating surfaces are important to locate ring
gear, differential case and cover correctly. Smooth
down burrs or high spots with an oil stone.
2. Heat tapered roller bearing to approx. 100 C/
212 F and install. Then press on tight.
2. Clamp differential in a vise, pull off second
tapered roller bearing and unscrew ring gear
bolts.
39 - 122
Printed in Germany
944
39
Tools
No.
Description
Special Tool
Remarks
Connector
----
39 - 122a
39
39 - 122b
944
Printed in Germany
944
39
Note When:
No.
Description
Qty.
Removing
Installing
Bolt
Case cover
Thrust washer
Position correctly
Diaphragm spring
Position correctly
Outer plate
Inner plate
(molybdenum coated)
Pressure ring
Differential gear
Threaded ring
10
Differential pinion
11
Differential shaft
12
Differential case
Special
Instructions
39 - 122c
39
944
b) Pressure Rings:
Guide tabs and bearing surfaces must
not be worn or scored excessively.
They must also slide easily in the
differential case.
c) Differential Gears:
Bearing surfaces for thrust washers must
not be worn and inner plates must slide
easily on splines of gears.
d) Plates:
Check inner and outer plates for wear.
Guide tabs of outer plates and teeth of
inner plates must not be worn.
a) Differential Case:
Check guide grooves for outer plates
and pressure rings for wear.
39 - 122d
Printed in Germany
944
39
Note
Diaphragm springs must be installed that
curved surfaces face out toward the joint
flange.
1 - Pressure ring
2 - Inner plate
3 - Outer plate
4 - Diaphragm spring
Determining Thickness of Plate Assembly:
It new parts are used, the thickness ot the
plate assembly has to be determined again.
39 - 122e
39
944
e2 + e2 = 4.2 mm
Note
If determined distance is more or less
than specified distance "e", install thicker
or thinner outer plates.
"e" below 4.2 mm = use thinner plates.
"e" above 4.2 mm = use thicker plates.
Outer plates are available in thicknesses
of 1.9 mm, 2.0 mm and 2.1 mm.
A = Connector (made locally)
Note
Plates are worn and have to be replaced, if
the specified torque is not reached with
the thickest outer plates.
39 - 122f
Printed in Germany
944
39
TOOLS
No.
Description
Special Tool
Universal gauge
VW 385
Centering disc
VW 385/2
Master gauge
VW 385/26 or VW 385/30
Gauge plunger
VW 385/13
VW 385/15
VW 382/10
VW 385/17
Dial gauge
US 1026 or US 1027
Adjusting device
VW 521/4
10
Measuring lever
VW 388
Remarks
39 - 123
39
No.
Description
Special Tool
11
Clamp
3022
12
Sleeve
VW 521/8
13
Clamp
VW 386 a
14
VW 387
15
End gauge
VW 385/28
16
Torque gauge
US 1064
39 - 124
944
Remarks
Printed in Germany
944
39
Location of Shims
Ro - Length of master gage used in special testing machine
"Ro" = 46.60 mm.
r
- Deviation "r".
39 - 125
39
Adjusting Pinion
1. Heat pinion bearing inner race (large bearing) to
about 100 C/212 F, install on pinion without
shim and press on with a force of about 3 tons.
2. Heat pinion bearing inner race (small bearing) to
about 100 C/212 F, install on pinion with 1.1
mm thick shim (arrow) and press on with force
of about 3 tons.
944
39 - 126
1.81 mm
+ 1.10 mm
+ 0.15 mm
+ 0.10 mm
= 3.16 mm
========
Printed in Germany
944
39
39 - 127
39
944
39 - 128
Printed in Germany
944
39
1.88 mm
- 0.32 mm
1.56 mm
=======
3.16 mm
- 1,56 mm
1.60 mm
=======
Shim
Shim to
Range be
installed
Part Number
Shim
Shim to
Range be
installed
Part Number
1.050 - 1.100
1.105 - 1.125
1.130 - 1.150
1.155 - 1.175
1.180 - 1.200
1.205 - 1.225
1.230 - 1.250
1.255 - 1.275
1.280 - 1.300
1.305 - 1.325
1.330 - 1.350
1.355 - 1.375
1.380 - 1.400
1.405 - 1.425
1.430 - 1.450
1.455 - 1.475
1.480 - 1.500
1.505 - 1.525
1.530 - 1.550
1.555 - 1.575
1.580 - 1.600
1.605 - 1.625
1.630 - 1.650
1.655 - 1.675
1.680 - 1.700
1.705 - 1.725
1.730 - 1.750
1.755 - 1.775
1.780 - 1.800
1.805 - 1.825
1.830 - 1.850
1.855 - 1.875
1.880 - 1.900
1.100
1.125
1.150
1.175
1.200
1.225
1.250
1.275
1.300
1.325
1.350
1.375
1.400
1.425
1.450
1.475
1.500
1.525
1.550
1.575
1.600
1.625
1.650
1.675
1.700
1.725
1.750
1.775
1.800
1.825
1.850
1.875
1.900
1.050 - 1.100
1.105 - 1.125
1.130 - 1.150
1.155 - 1.175
1.180 - 1.200
1.205 - 1.225
1.230 - 1.250
1.255 - 1.275
1.280 - 1.300
1.305 - 1.325
1.330 - 1.350
1.355 - 1.375
1.380 - 1.400
1.405 - 1.425
1.430 - 1.450
1.455 - 1.475
1.480 - 1.500
1.505 - 1.525
1.530 - 1.550
1.555 - 1.575
1.580 - 1.600
1.605 - 1.625
1.630 - 1.650
1.655 - 1.675
1.680 - 1.700
1.705 - 1.725
1.730 - 1.750
1.755 - 1.775
1.780 - 1.800
1.805 - 1.825
1.830 - 1.850
1.855 - 1.875
1.880 - 1.900
1.100
1.125
1.150
1.175
1.200
1.225
1.250
1.275
1.300
1.325
1.350
1.375
1.400
1.425
1.450
1.475
1.500
1.525
1.550
1.575
1.600
1.625
1.650
1.675
1.700
1.725
1.750
1.775
1.800
1.825
1.850
1.875
1.900
39 - 129
39
944
39 - 130
Printed in Germany
944
39
39 - 131
39
944
Checking Backlash
39 - 132
Printed in Germany
944
39
39 - 133
39
39 - 134
944
Blank Page
944
39
39 - 135
39
944
Removing
Note
When performing operations on the transaxle
system
that involve rotating or shifting the transaxle tube,
always wear leather gloves to avoid injuries
1. Take off rear wheels.
2. Disconnect battery ground lead.
6. Remove splash shield.
3. Disconnect parking brake cable on parking
brake
lever and pull back out of guide.
4. Loosen control cable on bracket and disconnect
on accelerator pedal.
39 - 136
944
39
Note:
Suspend starter from suitable point on car so that
the wire harness is not stretched.
39 - 137
39
944
Note:
Since the heater valve covers up the ground point,
the coolant must be drained partially and the
valve removed.
14. Unscrew screws for speed and reference mark
transmitters. Pull out transmitters while turning
back and forth at same time.
16. Mark position of flywheel/damper for reinstallation later or turn flywheel until marks in starter
opening are visible.
A - Wooden block
39 - 138
Printed in Germany
944
39
Note:
This step requires an extra person on the front bell
housing to balance the weight of the central tube
for safety's sake.
A - Adhesive tape
Installing
Note:
Installation marks (not TDC mark) on flywheel and
damper must be aligned. Before installing the
central
tube, turn flywheel and damper until installation
marks face down at an angle (toward starter
opening).
39 - 139
39
944
Note:
Transmitters have permanent magnets. Make sure
metal particles are not stuck on the transmitters
before installing.
Note marks of transmitters. Never use force to
install them.
39 - 140
Printed in Germany
944
39
39 - 141
39
944
Note When:
No.
Description
Qty.
Removing
Special
Instructions
Installing
Cap
Bolt
Torque:
80 Nm (58 ft Ib)
Bolt
Torque:
21 Nm(15 ft lb)
Washer
Bearing flange
Clamp
Cap
Bolt
Circlip
10
Spacer
Determine thickness if
necessary
11
Damper
12
Bolt
Torque:
42 Nm (30 ft lb)
13
Washer
14
Housing
15
Insulation sheet
Position correctly.
Coat mating surfaces
for body with assembly
paste (e. g. rubber
lubricant)
16
Central tube
Check, replacing
complete if necessary
Torque:
80 Nm (58 ft lb)
Note
When performing operations on the transaxle system that involve rotating or shifting the transaxle
tube, always wear leather gloves to avoid injuries.
39 - 142
944
39
39 - 143
39
944
39 - 144
Printed in Germany
944
39
39 - 145
39
944
Adjusting Damper
Note:
The damper is adjusted to an installed distance of
18 + 1.2mm by using spacers.
Make measurement according to following
procedures.
Example:
Measured distance from bell housing
edge to damper hub
Thickness of straight-edge
Measured result
Specified value
Deviation from specified value
25.00 mm
- 5.00 mm
20.00 mm
- 18.00 mm
2.00 mm
39 - 146
Printed in Germany