porsche 928 factory manual - volume 4

7/22/2019 Porsche 928 Factory Manual - Volume 4

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Workshop Manual

DR. ING. h. c. F. PORSCHE Aktiengesellschaft


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The Workshop Manual is only for the internal use of the Porsche Dealer Organization,

@ 1977 Dr. Ing. h.c. F. Porsche AktiengesellschaftSales, D-7140 Ludwigsburg

All rights reserved. - Printed in Germany Xx, 1988

WKD 481 621Print No. W 42-608-126-l


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List of Repair Groupsa General Technical Data Page 0.1

Repair Groups GroupMaintenance. Selfdiaanosis 03

Engine Engine, CrankcaseEngine, Crankshaft, PistonsEngine, Cylinder Head and Valve DriveEngine, LubricationEngine, CoolingFuel SupplyAir Flow Controlled Fuel InjectionExhaust System/Emission ControlsStarter, Power Supply, Cruise Controllanition Svstem

10131517192024262728

Transmission Clutch, Controls 30Torque Converter 32Manual Transmission, Controls, Case 340 Manual Transmission, Gears, Shafts 35Automatic Transmission, Contrds, Case 37Automatic Transmission, Gears, Valve Body 38Differential, Transaxle System 39

Chassis

BdY

Front Wheel Suspension 40Rear Wheel Suspension, Axle Shaft 42Wheels, Tires, Alignment 44Antiblock System 45Brakes, Mechanical 46Brakes, Hydraulics 47Steering 48Body-Front Section 50Body-Center Section 51Body-Rear Section 53Lids 55Doors 57Hardtop 61Bumpers 63Glasses, Window Control 64Exterior Equipment 66Interior Equipment 68seats 72Seat Covers 74

Heating,Ventilation,Air ConditionElectric8

HeaterVentilationAir ConditionerInstruments, Fuel Gauge, Alarm SystemRadioWindshield Wipers and WasherExterior Lights, Lamps, SwftchesInterior LightsWiring

808587909192949697

l Printed in Germany - XX, 1987


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928 Table of contents Volume IV

Front wheel suspensionPage

Technical data ....................................... 40-01Tightening torques ..................................... 40-02Notes on front axle, 86 models onward .......................... 40-04Disassembling and assembling wheel suspension ..................... 40-lDisassembling and assembling wheel suspension, until end of model year 85 ...... 40-2Disassembling and assembling wheel suspension, 86 models onward .......... 40-7Disassembling and assembling wheel suspension (before and after model year 86) 40-13Wheel suspension components - installation overview .................. 40-16Modifications to mountings ................................. 40-19Closing slots in ball joints .................................. 40-23Inspecting protective caps of ball joints on control arms and track rods ......... 40-24Modified steering knuckle, cars with floating brake calipers ................ 40-25Disassembling and assembling wheel bearing ....................... 40-27Removing and installing spring strut ............................ 40-35Disassembling and assembling spring strut, tools ..................... 40-35Disassembling and assembling non-adjustable spring strut ................ 40-37Disassembling and assembling adjustable spring strut .................. 40-39Disassembling and assembling adjustable and non-adjustable spring struts ....... 40-42Coil springs for adjustable spring struts .......................... 40-46Coil springs for non-adjustable spring struts ........................ 40-47Coil springs for non-adjustable struts/effect on car height ................. 40-49Dampers - installation overview .............................. 40-51Rear Wheel Suspension, Axle ShaftTechnical dataTightening torquesDisassembling and assembling rear suspensionDisassembling and assembling Hub assemblyReplacing upper control arm mountRemoving and installing spring strutDisassembling and assembling spring strutDamper installation overviewRemoving and installing axle shaftDisassembling and assembling axle shaftRemoving and installing rear axle assembly

Wheels, Tires, AlignmentWheels and tires, pressure17-inch wheelsAlignment settings

...... 42-01

...... 42-02

...... 42-1

...... 42-7

...... 42-13

...... 42-14

...... 42-15

...... 42-l 8d

...... 42-19

...... 42-21

...... 42-29

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

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

.................44-0144-0344-05

Table of contentsPrinted in Germany - XXXV, 1996

1


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Volume IV Table of contents 928

PageSample measuring card .................................. 44-06Alignment ......................................... 44-1Checking wheel rims ................................... 44-6General assembly information, tires ............................ 44-7Wheel balancing ...................................... 44-10Installing and removing wheels on car .......................... 44-19Tire pressure warning system - General ......................... 44-21Tire inflation pressure for vehicles with tire pressure warning system .......... 44-26Tire pressure warning system short test ......................... 44-28Removing and installing pressure-operated switches (tire pressure warning system) 44-29Removing and installing high-frequency sensor (tire pressure warning system) 44-32Removing and installing tire pressure warning system control unit. ........... 44-33Connector assignment of the control unit connector ................... 44-34Notes on trouble-shooting - Tire pressure warning system ................ 44-35Tire pressure warning system (RDK) diagnosis. ..................... 44-301Aritiblock SystemGeneralDesign - ABSComponents - ABSImportant notes for troubleshooting and ABS test programImportant information for working on cars with ABSRemoving and installing hydraulic unitRemoving and installing electronic control unitRemoving and installing relaisRemoving and installing sensorsRemoving and installing speed sensor, 86 models onwardBrakes I MechanicalGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ., 46-01Technical data 46-02Technical data, 86 models onward 46-05Torque specifications 46-08

45-0145-0345-0445-0645-0745-145-545-645-845-11

2 Table of contentsPrlnted In Germany - XXXV, 1996


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929 Table of contents Volume IVaTechnical data as of MY 92Checking thicknesss of brake padsRemoving and installing brake pads (Floating frame caliper disc brakes)Removing and installing brake pads (floating caliper disc brakes)Removing and installing brake pads (four-piston fixed caliper)Removing and installing brake pedalAdjusting brake pressure rod (until end of model year 85)Adjusting brake pressure rod (86 models onward)Checking stoplamp switch settingDisassembling and assembling front wheel brakeDisassembling and assembling rear wheel brakeChecking brake disc lateral runoutChecking brake disc thicknessDisassembling and assembling parking brake leverChecking and adjusting parking brake

Page46-01146-146-246-546-6b46-846-946-1046-10a46-l 146-1346-1646-1846-1946-21

Brakes I HydraulicsTightening torques ................................... 47-01Notes on brakes, 86 models onward .......................... 47-03Disassembling and assembling floating frame caliper ................. 47-lDisassembling and assembling fist caliper ....................... 47-7Replacing dampers and slides ............................. 47-12Removing and installing brake master cylinder .................... 47-13Removing and installing brake booster. ........................ 47-15Removing and installing brake pressure regulator ................... 47-17Braking-force regulators - installation overview (until end of model year 83) ..... 47-18aBraking-force regulator installation overview (84 models onward) .......... 47-1813Testing braking-force regulator ............................. 47-19Notes on bleeding brakes and changing brake fluid .................. 47-22SteeringTechnical dataTorque specificationsRemoving and installing steering gearSteering stop versionsRemoving and installing power steering pumpReplacing seals for aluminium power steering pumpNotes on power steering:Checking drive belt tensionChecking steering system for leaks

48-0148-0248-l48-6a48-748.8a48-8i48-8148-81

Table of contentsPrinted in Germany-XxX, ,996

3


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Volume IV Table of contents 928

Bleeding steering systemChecking hydraulic function of steering (pressure test)Removing and installing steering wheelRepairing steering and intermediate shafts with steering tubeReplacing upper steering shaft bearingDismantling and assembling steering wheel height adjuster of airbag vehiclesHeaterHeater, blower, air distribution housing ............ ....... 80-lAir ConditionerSpecifications ......................................Tightening torques ....................................Refrigerant system layout ................................Vacuum system layout .............. ............. ......Safety regulations for handling refrigerant R12 .....................Installation work on the air-conditioning system (Service unit SECU)Removing and installing heater I evaporator ......................Removing and installing blower ............. ............. ...Removing and installing air distribution housing ............ ........Disassembling and assembling heater I evaporator .............. ....Removing and installing condenser fanRemoving and installing receiver-drier ............ .............Removing and installing compressor ..........................Disassembling and assembling compressor ......................Regulators and control unit of automatic air conditioner ............. ...Disassembling and assembling center vent and switchAutomatic a ir conditioner 84 models onward .............. ........Technical data ......................................Tightening torques ....................................Disassembling and assembling heater / air conditionerRemoving and installing heater I air conditioner .............. ......Removing and installing compressor ..........................Removing and installing condenser .............. .............Removing and installing fluid tank. .............. .............Removing and installing antifreeze unit .............. ...........Removing and installing expansion valve / Distribution of oil in refrigeration circuitVacuum system - schema ................................Checking vacuum system ................................Flap position program .............. .............. ......Checking flap position program ............ .............. ...Checking operating switch. ............. ............. .....Testing setting motor .............. .............. ......

87-0187-0287-l87-287-387.4b87-587-1687-1787-l 987-2487-2587-2887-3187-4387-4787-8987-9087-9187-9287-9787-9987-10087-10187-10287-10387-10487-10587-10687-l 0887-11087-113

Page48.8k48-948-1448-l 548-3048-33

4 Table of contentsPrinted In Germany-XXX, ,996


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928 Table of contents Volume IV

PageAdjusting temperature m ixture flaps ............... ............. 87-115Pressure and temperature specifications ............... ........... 87-116Troubleshooting ....................................... 87-118Auxiliary air conditioner ................................... 87-120Removing and installing magnetic clutch ................. ......... 87-126Technical Data of air conditioning system as of MY 93 .... .............. 87-129

a Table of contents 5Printed in Germany - XXXV, 1995


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l

928 Front Wheel Suspension 40TECHNICAL DATA

Front Axle

Suspension

Springs

DampersMake/installation

Stabilizersuntil end of model year 7980 models onward86 models onward

Independent suspension, doublecontrol arrr with coil spring and internaldamper.

1 coil spring per wheel

Double-action hydraulic dampersSee page 40 - 51

dia. 26 mmdia. 28 mm x 4 (tubular stabilizer)dia. 28 mm x 4 (tubular stabilizer)with modified knuckle

aPrinted in Germany - XIII, 1986 Technical Data 40 - 01


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40 Front Wheel Suspension 928TIGHTENING TORQUES FOR FRONT AXLE

Location Description Thread Material

Upper controlarm to body VM 14x1.5 8

Lower controlarm to body,rear

Self-lockinghex nutHex bolt M 12x1.5 10.9

Lower controlarm to body,front

Hex bolt M 12x1.5 8.8 85 (62)

Guard tolongitudinalmemberSelf-lockinghex nut VM 10 8 46 (33)

Spring strutto body Self-lockinghex nutSelf-lockinghex nut

VM 10 8 46 (33)

Spring strutand stabilizerlinkage tolower controlarm

VM 12x1.5 8 85 (62)

Stabilizerclamp tolongitudinalmember

Hex bolt M 10 8.8 46 (33)

Stabilizerlinkage tostabilizerSelf-lockinghex nut VM 12x1.5 8 85 (62)

Upper andlower controlarms tosteeringknuckle

Flangelocknut

M 12x1.5 8 65 (47)

Guard tosteeringknuckleHex bolt M7

Cable holderto steeringknuckleHex bolt M7

8.8

8.8

TorqueNm (ftlb)

140 (103)

120 (88)

15 (11)

15 (11)

040 - 02 Tightening Torques Printed in Germany


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928 Front Wheel Suspension 40

Location

Brake caliper tosteering knuckleBrake disk towheel hubPanhead bolt toclamping nutWheel to wheell hubSteering trackrod to steeringarmRubber bushingof piston rodof spring strutBall joint,(mounting) tolower controlarmSupport plateon steeringaxle (uppercontrol arm)a Roadspeed sensorto steeringknuckle

Description

Hex boltPanhead boltCountersunkboltPanhead bolt

Wheel nutHex nut,self-locking

Hex nut,self-locking



Panhead bolt

Thread

M 12x1.5

M6

M7

M 14x1.5VM 12x1.5

VM 12x1.5

VM 12x1.5

VM 12x1.5

M6

Material

8.8

8.8

10.9

Al8

8

10

8

8.8

TorqueNm (ftlb)85 (62)

10 (7)

15 (11)

130 (95)65 (47)

60 (44)

120 (88)

85 (62)

10 (7)

Printed in Germany - XIII, 1986 Tightening Torques 40 - 03


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40 Front Wheel Suspension 928NOTES ON FRONT AXLE, 86 MODELS ONWARDNew front wheel suspension

1 2

13

9-

40 - 04 Notes on Front Axle, 86 Models Onward Printed in Germany


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Front Axle Modifications,86 Models Onward

No./Description1 Steering knuckle

l- Wheel bearing

- Steering offset

2 Upper control arm

a 3 Dampers

Most Important ModificationsAttachment points for brakecaliper

Studs for wheel bearing(clearance and diameter forouter bearing)Locator for ball jointNo. 10 of the mountingOuter wheel bearing larger.Distance between bearingsincreased

- 10.2 mm before - 16 mm

Shorter than before. Balljoint inclined outward

Adjustment2-pipe gas-filled dampers(Boge) standard and optionalpreviouslystandard:Z-pipe pressureless (Boge)optional:l-pipe gas-filled (Bilstein)

RemarksFour-piston fixedcaliper, 86 modelsonward

Adjust as before(every 20000 km)

For braking system(four-piston fixedcaliper)Heights and wheelgeometry unchanged

Distinguishingfeature,P. 40 - 16/17

Table P. 40 - 51Combination withcoil springs up to86 models imper-missible

Printed in Germany - XII 1, 1986 Notes on Front Axle, 40 - 0586 Models Onward


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40 Front Wheel Suspension 928No./Description

4 Coil springs

7 Stabilizer linkage

- Stabilizer

8 Steering track rods

9 Mounting (steel)

11 Camber and castereccentrics (sameparts)

12 Lower control arm

13 Spring strutstirrup

Most Important Modifications

spring rate increased

longer than before

modified knuckle

approx. 1Omn shorter thanbefore

upright ball joint (pre-viously trailing ball joint)

external contour smaller

shorter than before

modified mounting point forspring strut, because con-trol arm shorter but strutposition same as in carsearlier than 86 models

Remarks

Only for Boge gasdampers.Combination withdampers up to 86models or Bilsteindampers imper-missible P. 40 - 46

P. 40 - 16/ 40 - 18

P. 40 - 16/18

P. 40 - 16/17

P. 40 - 19 to40 - 21

External eccentricA = cambereccentricInternal eccentricB = castereccentricP. 40 - 21

Distinguishingfeature/code P. 40- 16/17

Distinguishingfeature/codeP. 40 - 19 to40 - 21

a40 - 06 Notes on Front Axle, 86 Models Onward Printed in Germany


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928 Front Wheel Suspension 40TOOLS

No. Description Special Tools Remarks

1 Press-out tool VW 267 a2 Track rod puller e.g. Nexus 168 - 1

Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 1Wheel Suspension


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&&& b.--.*e -.*,kZ%ZY-_z+.cz&Fyz lo~=L--/4 ,n~5 ~$/g=+c )J-. I 9/-/ S\I?h ~,_ 2,_I*_

F-1;p: Yn /-&&A 7.6 ./6 I 0, fT>-2s

/- I,tc. ; : *\,I&


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928 Front Wheel Suspension 40No-

1

l33i

4 Locknut

5 Washer

6 Locknut

Description

Locknut

Washer

Flange locknut(for steeringknuckles withoutpush-off lug forball joint)or

Flange locknutCap locknut (onsteering knuckleswith push-off lugfor the lowerball joint). (Seepage 40 - 25)

Washer, 928 Sonly (floatincaliper brake 3

Air guide plate,928 S (floatingcaliper brake)

ItY-3

3

2

11

2

1

1

1

1

Note When:Removing

load ball joint byaxerting pressure onJpper control arm

to ease installation,see removing as for36 models onward(p. 40 - 8)

Installing

renew, torque: 46 Nm(33 fltb)

renew, torque: 65 Nm(47 ftlb). Exertpressure on uppercontrol arm to loadball joint

renew, torque: 140 Nm(103 ftlb)

only on rear pin o fcontrol arm


Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 3Wheel Suspension, UntilEnd of Model Year 85


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78

9

10

11

12

13

14

15

Description QtrHex boltStabilizerlinkage

Upper controlarm

Spring strut

Steering knuckle

Locknut

Caster/cambereccentrics

Camber/castereccentric

Ball joint(mounting)

Note When:Removing Installing

when replacing, do notconfuse with versionfor 86 models onward.Installation overview,pages 40 - 16 to40 - 18

inspect, renew ifnecessary, reworkingis impermissible

inspect for damage,reworking is imper-missibleSee page 40 - 25


lubricate sliding suf-faces of eccentric ad-justment range withOptimoly TA. Coverball joint slots. Seepages 40 19, 40 - 20and 40 - 23

see pages 40 - 19 and40 - 20 for positionand types.

inspect, renew ifnecessary. Cover slot,see pages 40 - 19,40 - 20 and 40 - 23

040 - 4 Disassembling and Assembling Wheel Printed in GermanySuspension Until End of Model Year 85


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928 Front Wheel Suspension 40No-16

17 Locknut

18 Hex bolt

19

20

21

22

Description

Clamp

iex bolt(10.9, 80 nnn long]

dasher approx.S mm thick, dia.approx. 30 nm

Bearing clamp

Hex bolt(100 mm long)

!U-1

2

2

2

2

1

2

* See notes on page 40 - 14

Note When:lemoving Installing

see pages 40 - 19 and40 - 20


Coat threads with3ptimoly HT (do notapply Optimoly HT tobolt shank).* Screw inuntil only 2 threadsare visible. Do nottighten to 120 Nm (88Fltb) until assemblyis completed andsprings have settled

do not mix up withMasher No. 23

inspect for damage.Tighten to specifiedtorque

Coat thread with Opti-moly HT. (Do not applyOptimoly HT to boltshank).* Torque: 85 Nm(62 ftlb)

Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 5Wheel Suspension Until End ofModel Year 85


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40 Front Wheel Suspension 928No.

23

24

25

Description

Washerw;;x. 4 mmdia. approx.25 nm

Guard

Lower control armwith*spoilersecuring boltscup washerssecuring bracketslocknuts

BYNote When:Removing Installing

do not mix up withwasher No. 20

renew if damage sus-pected. No reworkingis permissible.Tighten bolts No. 19of bearing clamp No.21 as specified. Whenreplacing, do not con-fuse with control armfor 86 models onward.Installation overview,Pages 40 - 16 to40 - 18

* 928 S only (floating caliper brakes)

40 - 6 Disassembling and Assembling Wheel Printed in GermanySuspension, until End of Model Year 85


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: ,+&c -flGPJ I

&-- ~._SZ-_cc ,),-/it

=-.+:. --- -!i< J

a~~~*-A /6 A-.

9 ?2ygq)i 15_.

1 -$I

20

12 6L

" M-13

I:11 > ! I10 3, 1 \',


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40 Front Wheel Suspension 928No,

1

2

3

4

5*

6

7

8

Description

Locknut

Washer

Speed sensorwith O-ring andmounting bolt

Hex bolt withspring washer

Flange locknut

Flange locknut

Steering knuckle

Locknut

NY-3

3

1

1

1

1

1

2

Note When:Removing

If necessary, loadball joints byexerting pressure onupper control arm

As No. 5 4s No. 5

If necessary (toincrease workingspace), removebearing clamp No. 25of lower control arm.When removing bearingclamp, slacken lock-nuts No. 17 on casterand camber eccentrics.

Installing

Renew, torque: 46 Nm(33 ftlb)

:oat speed sensor andhole in steeringknuckle with Molykote-0ngterm 2. Renew O-rina of soeed sensor.Tightening torque forIllen-head bolt 10 Nm(7 ftlb)

renew, torque: 65 Nm(47 ftlb). Load balljoints by exertingpressure on uppercontrol arm

inspect for damage. Noreworking isoermissible.


* There is no difference between No. 5 and No. 6 (collar dia. approx.24 mm). In some cars, a nut (No. 5) with a collar dia. approx:26,mm wasfitted to the upper joint (to use up stock).

a40 - 8 Disassembling and Assembling Wheel Printed in GermanySuspension, 86 Models Onward


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9

10 Locknut

11

12

l 1314

l15

16 Spring strut

Description

Washer

Washer

Rir guide plate

Hex bolt

Stabilizer link-age

Upper controlarm

QW-1

Note When:lemoving Installing

only on rear controlarm mounting


when replacing, do notconfuse with versionfor cars earlier than1986. Spare partnumber on linkage.Tightening torque forupper and lowermountings : 85 Nm(62 ftlb).Install right wayround. Cranked end attop (at spring strutmounting) and tiltedforward (no differencebewteen left-hand andright-hand parts).

inspect, renew ifnecessary. No re-working is permis-sible. Attachment tobody: lubricate threadand shank with Opti-moly HT.

Coil spring page 40-46Damper installationoverview, page 40-51

Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 9;;;;idSuspension, 86 Models


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40 Front Wheel Suspension 928No,-17

18

19

20

21

22

Description

Locknut

Caster or cambereccentric (outereccentric - camber

Ball joint(mounting)

Clamp

Locknut

Hex bolt

tY-2

2

1

1

Note When:?emoving

only slacken if partof control arm with:lamp and ball joint[mounting) must bereplaced

oat sliding surfacesf eccentric adjust-ent range with Opti-oly TA.over slots of ballDints, page 40 - 23.hen replacing, noteage 40 - 21.'

il nspect, renew ifntecessary. Close slot,P'age 40 - 23

WImfm'PiC,tHm0ti

hen replacing, do notix up with versionor cars earlier thanode1 year 86. Seeage 40 - 21. Afternserting in lowerontrol arm, coathread with OptimolyT. Do not allow Opti-oly HT to touch shankf bolt or to pene-rate hole in light-lloy member (see page0 - 14).

enew, torque: 46 Nm33 ftlb)

nstalling

enew, torque: 120 Nm38 ftlb)

l40 - 10 Disassembling and Assembling Wheel Printed in GermanySuspension, 86 Models Onward


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928 Front Wheel Suspension 40No-23 t

25

26

27

28

Description QtyHex bolt (10.9/80 mm long)

Washer approx. 6mm thick,dia. approx.30 mm

Bearing clamp

Hex bolt(100 mm long)

Washery;x. 4 mmdia. ipprox.25 mmGuard

Note When:Lemoving Installing

coat thread with Opti-moly HT (Optimoly HTon bolt shank is im-permissible).* Screwin until only 2threads are visible.Do not tighten to 120Mm (88 ftlb) untilassembly is completedand springs havesettled.

do not mix up withMasher No. 27

check for damage.Tighten as specified.

coat threads withOptimm(OptimolyHT is not permissibleon bolt shank)*Torque: 85 Nm (62ftlb)

do not mix up withwasher No. 24

* See note page 40 - 14

Printed in Germany - XIII, 1986 Disassembling and AssemblingWheel Suspension, 86 ModelsOnward40 - 11


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Front Wheel Suspension 928

No.-29

Description

Lower controlarm with spoilersecuring boltscup washerssecuring brack-etslocknuts

tY-1

Note When:?emoving Installing

Renew if damage sus-pected. No reworkingis permissible.Tighten bolts No. 23of bearing clamp No.25 as specified.When replacing, do notmix up with controlarm for cars earlierthan model year 86.Part marked "Porsche"(before 86 modelyears, without Porscheinscription).Installation overview,see pages 40 - 16/40 - 17

a40 - 12 Disassembling and Assembling Wheel Printed in GermanySuspension, 86 Models Onward


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928 Front Wheel Suspension 40a

INSTRUCTIONS FOR ASSEMBLY AND DISASSEMBLY

Disassembling

l.Unbolt brake caliper and moveaside without imposing strain onbrake hose.Mounting: until end of model year85

p!l!FF-/--

Mounting: 86 models onwardBeforehand, open plug-in connectorof ABS and brake-pad wear cable anddisconnect.

3/ 493Z.Disconnect ground lead (86 modelsonward). Remove speed sensor.

3.Press out track rod withextractor, e.g. Nexus 168-1.

Printed in Germany - XIII, 1986 Disassembling and Assemblin % 40 - 13Wheel Suspension (Before anAfter Model Year 86)


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40 Front Wheel Suspension 9284.Use VW 267a to press out balljoint. Take care not to damageprotective caps of joints.(Steering knuckle with cap nut,

see page 40 - 25). If co llar nutsdifficult to remove, seeInstalling, Item 3.

w-

Wheel suspension, 86 models onward(lower ball joint).

InstallingNote:When using Optimoly HT or TAassembly paste, note the following:

Optimoly HT (copper-colored)For steel-steel threaded connec-tions and contact surfaces ofassembly parts.Never use Optimoly HT on contactsurfaces of steel to light alloy,as moisture will produce corrosion.When applied to threads, this lub-ricant has no effect on tighteningtorques.

Optimoly TA (aluminum color)For all connections with aluminumor with magnesium, for corrosionprotection.When applied to threads, thislubricant has a slight effec t ontightening torques.

l.Subject all parts to visualinspection, if necessary, comparewith new part.If replacement parts are fitted,check installation overview, seepages 40 - 16 to 40 - 21

a40 - 14 Disassembling and Assembling Wheel Sus- Printed in Germanypension (Before and After Model Year 86)


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928 Front Wheel Suspension 402.When installing lower controlarm, screw bolts of rear bearing Close slots for outer cams (page40 - 23).clamp into body until only 2threads are visible.

Do not tighten the two bolts tospecified torque until assemblyis completed and springs havesettled. This keeps front of cardown.

3.To prevent ball pins turning andto allow installation of collarnuts (also for disassembly),apply pressure to upper controlarm to load ball joints.

a Note:Spray adjustmentcontrol arm withthreaded section

plate on lowereccentrics,of track rod,upper bearing._hreaded pins injoint and threaded pins in lowerbearing joint with Tectyl-UL 846(Valvoline). This preventscorrosion of the threaded elements,thus facilitating maintenance andrepair work.

Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 15Wheel Suspension (Before andAfter Model Year 86)


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40 Front Wheel Suspension 928WHEEL SUSPENSION COMPONENTS INSTALLATION OVERVIEW*

Fig. DescriptionNo.

1 Upper control arm

2 Lower control arm

5

Track rod

Stabilizer linkage

Stabilizer

Identification - Distinguishing Features**

Version Auntil end of modelyear 85

longer than 86models onward, balljoint at right angleto suspension link

longer than 86models onward, noidentificationmarking

longer than 86models onward

shorter than 86models onward,marked with spare-part number

stabilizer knuckleshorter and lesscranked than 86models onward (untilend of model year79, solid stabil-izer, 80 modelsonward, tubularstabilizer)

Version B86 models onward

shorter than untilend of model year85, ball joint in-clined outward

shorter than untilend of model year85, bears"Porsche" inscrip-tion

shorter than untilend of model year85

longer than untilend of model year85, marked withspare-part number

stabilizer knucklelonger and morecranked than untilend of model year85a

* Mounting, clamp, camber and caster eccentrics, pages 40 - 19 to 40 - 21** Dimensions, see pages -0 17 and 40 - 18.

a40 - 16 Wheel Suspension Components - Printed in GermanyInstallation Overview


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928 Front Wheel Suspension 40Version Auntil end of model year 85 Version B86 models onward

1 Upper control arm

2 Lower cdntrol armI

No "Porsche"inscriptionDim. X = 191 mm

With "Porsche"inscriptionDim. X = 179 arm

I3 Track rodDim. X approx. 245 mm Dim. X approx. 235 mm

Printed in Germany - XIII, 1986 Wheel Suspension Components - 40 - 17Installation Overview


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40 Front Wheel Suspension 928Version Auntil end of model year 85 Version B86 models onward

aI4 Stabilizer linkage

Spare Part No. (arrow) Spare Part No. (arrow)928 343 069 00 928 343 069 01Dim. X approx. 135 run Dim. X approx 142 rmn

ADim. a = 95 + 3 mmDim. b = 38 z 1 mm

I5 StabilizerDim. a = 102 + 3 mmDim. b = 43 T 1 mm-

a40 - 18 Wheel Suspension Components - Printed in GermanyInstallation Overview


33/458

928 Front Wheel Suspension

aMODIFICATIONS TO MOUNTINGS/NOTES FOR REPLACEMENT

Until end of model 85ball joints were installed on theYfFokraxle. mounting: with trailing1 . ,I .. 3 l lY ll l, lA; of Seotemtmountings were used instead of aluminum. )er 1983, steelThis change also necessitated a modification of the camber and castereccentric retaining clamps. The caster and camber eccentrics installed withthe steel mountings are identical parts and are distinguished from theearlier versions by the stamped part No. 928 341 466 00.

Steel mountings with upright ball joints were installed from m o d e 1year 86 o n w a r d (modified wheel suspension). This modificationincluded redesigning retaining clamps and camber and caster eccentrics(retaining clamp with modified mounting point for spring strut, as controlarm shorter but same strut position as in cars earlier than model year 86).There is no difference between caster and camber eccentrics, which aredistinguished from the original and modified versions by the stamped partNo. 928 341 466 01.

Mountings until End of Model Year 85

Parts Overview:

Fig. DescriptionItem* Original Version Modified Version

: Mountingeft-hand 928.341.049.1028.341.091.03 928.341.049.12clamp 928.341.091.05: Casteright-hand ccentriclamp 928.341.453.0028.341.092.03 928.341.092.05928.341.466.004 Camber eccentric 928.341.455.00 928.341.466.00

* See Fig. on page 40 - 20

Printed in Germany - XIII, 1986 Modifications to Mountings 40 - 19


34/458

40 Front Wheel Suspension 928Mountings until End of Model Year(Parts Overview, page 40 - 19)

Original Version Modified Version

3, ~~G& ? -iF, i &A, .-,: d/SJ,' 2 , /// A'-'4 1" ._

085

1q, y.: : 3+4

216,/- -\4 j44.J ,I cli3 4 3+4

The position of the eccentrics has been changed to suit the modifiedmountings. Caster is now set at the inner and camber at the outereccentric.

The original type of mounting has now been discontinued. The modifiedversions may be retrofitted to these cars.

Original and modified parts are not interchangeable. This means that when amodified mounting is installed in an older car for the first time, newclamps and eccentrics must also be used.

It is permissible to install a modified mounting on one side only.

Under no circumstances may clamps for cars of model year 86 onward be useddanger of confusion, see note on page 40 - 6e .

40 - 20 Modifications to Mountings Printed in Germany


35/458

928 Front Wheel Suspension 40Mountings, 86 Models OnwardParts Overview

1 Mounting; Clamp, leftClamp, right3+4 Camber and castereccentrics

928.341.049.08928.341.091.06928.341.092.06928.341.466.01

As with the steel mountings in cars earlier than model year 86, the casteris set at the inner and the camber at the outer eccentric.It is essential to ensure that incorrect parts are not installed. There isa danger of mixing up modified and new/current parts. Example: if thewrong clamp is mounted, the installation position of the spring strut isincorrect and the clearance between spring strut and upper control arm maybe impaired.

Distinguishing Features Identifi-cation Marking of the Midified andNew/Current ComponentsModified version (until end ofmodel year 85)Clamp: 2 beads at front (arrows)Eccentric: stamped part No.928.341.466.00

New/current version, 86 modelsonwardClamp: No beads at frontEccentric: stamped part No.928.341.466.01

-cl28

\i

(

Printed in Germany - XIII, 1986 Modifications to Mountings 40 - 21


36/458


a

CLOSING SLOTS IN BALL JOINTSAs of September 1982, plastic sealing cord is used to close the slots forthe outer setting eccentrics of the front-axle ball joints of new cars. Inthis way, dirt is prevented from penetrating the joint, making theeccentric easier to operate when servicing.

If work has been carried out on the front axle, and especially afterrealignment of the wheels, close the slots for the outer eccentrics withpermanently-elastic sealing material on all cars (arrows). The sealingcord, part No. AKD 522.009, used to seal the 924 and 944 taillamps issuitable for this application.Before sealing, ensure that slots are dry and free o f grease.

If eccentric does not move freely(dirt in slot) we recommendremoval of the outer eccentric,cleaning of the slot and sprayingwith rust remover. Apply OptimolyTA to sliding surface of eccentricin adjustment area and reinstalleccentric.

Important:Never try to free eccentric by hitting ball joint. Impact may damage therubber cap.If.the rubber cap of a ball joint is damaged, it is essential to replacethe joint. See also "Inspecting Protective Caps of Ball Joints of ControlArms and Track Rods" (page 40 - 24).

Printed in Germany - XIII, 1986 Closing Slots in Ball Joints 40 - 23


37/458

40 Front Wheel Suspension 928INSPECTING PROTECTIVE CAPS OF BALL JOINTS ON CONTROL ARMS AND TRACK RODSThe rubber protective caps of the front-axle ball joints may be damaged byexternal influences, e.g. flying stones, or during assembly.If a protective cap is damaged, the joint in question - upper or lowercontrol arm, track rods - must be renewed, as the action of dirt ormoisture will destroy the joint. For this reason, we also call attention tothe routine listed in the vehicle maintenance plan:

"Inspect seating and operation of all joints to steering gear, track rods,suspension links and joints, as well as the leaktightness of the protectivecaps".

We recommend that the protective caps of the joints be checked wheneverwork is carried out on the front axle (visual inspection).Inspecting Rubber Protective Caps ofControl Arm Ball Joints:l.Raise car on hoist, steering lock disengaged.2.Turn front wheels to lock.3.Inspect visible areas on left and right after cleaning. Concealed cracksare revealed by pinching the rubber cap with the fingers.4.Turn front wheels to opposite lock and inspect other half of rubber caps.

In the vicinity of the brake cover plates, a small area cannot be inspectedvisually. Check this area by hand.

Upper ball joint Lower ball joint

40 - 24 Inspecting Protective Caps of Ball Joints Printed in Germanyon Control Arms and Track Rods


38/458

a

928 Front Wheel Suspension 40MODIFIED STEERING KNUCKLE, CARS WITH FLOATING BRAKE CALIPERS

To avoid damaging the rubber boot of the lower ball joint (mounting) with acommercial puller, the steering knuckle has a press-off lug (only steeringknuckles for floating brake calipers).

Steering knuckles without press-off lug have been discontinued and are nolonger available as spare parts.It is permissible to install the newest steering knuckle on one side only.

Disassembly

Lower Ball JointWhen the securing nut is slackened(cap nut - previously normalself-locking hex nut) the pin ofthe ball joint is pressed out ofthe steering knuckle, because thecap nut acts against the press-offlug.

Upper Ball JointUse VW 267 a to press off as before(page 40 - 14).

Printed in Germany - XIII, 1986 Modified Steering Knuckle, 40 - 25Cars with Floating Brake Calipers


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928 Front Wheel Suspension 40aTOOLS

T i, 1 4 2i/ P__*-

l No. Description1 Multi-purpose tool2 Puller3 Pressure piece4 Pressure piece5 Pressure plate6 Pressure piece7 Pressure plate

7 6 5 3

Special Tools

VW 7719165P 859154VW 447 iVW 433VW 511

Remarks

Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 27Wheel Bearing


40/458

40 Front Wheel Suspension 928 a

I7Notes:

I I10 14

a

lLi6 51 !a

- The exploded drawing shows the front-wheel bearing arrangement of carswith sliding calipers.

- If the front axle is equipped with floating calipers, brake caliper,brake disk, guard and steering knuckle are of different appearance andsize.

- The following components of four-piston fixed-caliper brakes differ inappearance and size: brake disk, brake caliper, mounting bolts forcaliper, outer wheel bearing, wheel hub, guard and steering knuckle.

40 - 28 Disassembling and Assembling Printed in GermanyWheel Bearing


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No.

2a

6

Description

Mounting bolt(hex bolts forsliding andfloatingcalipers)(Panhead boltsfor four-pistonfixed caliper)

Spring washer orwasher of four-piston fixedcaliper

Brake caliper

Hub cover

Clamping nutwith Allen bolt

Thrust washer

Outer wheelbearing (largeras of 86 models)

WY

2

2

1

1

1

1

1

Note When:Removing

Do not remove brakehose when workingon front-wheelsuspension, attachto suitable pointwith wire

Drive out withmulti-purpose toolVW 771 and 9165

Installing

Coat threads withOptimoly HT. Torque:85 Nm (62 ftlb)

Renew if necessary

Adjust play in wheelbearing. TightenAllen bolt, torque:15 Nm (11 ftlb)

Inspect, renew ifnecessary, applycoating of ShellRetinax A multi-purpose grease



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40 Front Wheel Suspension 928No. Description RY

8

9

10

11

12

13

Front-wheel hub(modified wheelbearing, 86models onward.No. of teeth onimpulse ring forABS: 45 insteadof 90).

Radial seal

Wheel bearing,inner

Countersunk bolt

Brake disk

Bearing race forouter wheelbearing

Models earlierthan end of 85

86 models onward

Note WhenRemoving

Press out with Renew. Press in withscrewdriver. Take VW 433 and 9154.care not to damage Place VW 511 underseat and impulse wheel hub as support.ring (vehicles with Pack recess with aABS) Shell Retinax A

If difficult to re-move, see P. 46-11

Heat wheel hub to Heat wheel hub to 120120 to 150c to 150C

Press out withpressure piece9154. Place pres-sure plate VW 511beneath wheel hubas support

Drive out by Place in position,placing drift in press in witheach of the suitable pressuregrooves in turn piece, e.g. VW 432

Installing

Clean centeringsurface for brakedisk and apply thincoat of Optimoly TAassembly paste. Packrheel bearing andwheel hub with ShellRetinax A

Inspect, renew ifnecessary, apply coatof Shell Retinax A

Place in position,press in withpressure piece 9154

a40 - 30 Disassembling and Assembling Printed in GermanyWheel Bearing


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No. Description PtY

14 Bearing race forinner wheelbearing1

15a

16

17

18

Hex bolt of- slidingcaliper- floatingcaliper- four-pistonfixed caliper

Spring ring orspring washer

Guard (dependinon brake system 3Steering knuckle(design dependson brake system)

Heat wheel hub to120 to 150C. Pressout with P 85 and9154. As of 8Cmodels, the racecan also be re-moved using a driftplaced in thegrooves.

Heat wheel hub to 120to 150C. Place inposition and press inwith pressure plateVW 447 i and pressurepiece 9154. Use VW511 as support.

Torque: 15 Nm (11ftlb). Coat threadwith Optimoly HT.

2-4 Renew if necessary

Inspect front wheelbearing for 15 wear.Remachining isimpermissible


aPrinted in Germany - XIII, 1986 Disassembling and Assembling 40 - 31Wheel Bearing


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NOTES ON DISASSEMBLY AND ASSEMBLY

Disassemblingl.Drive off hub cover with multi-purpose tool VW 771 and 9165. 4a.Cars earlier than end of modelyear 85: press bearing racesout of wheel hub.

Bearing race for outer wheelbearing

2.Use a large screwdriver to leveroff radial seal. Take care toavoid damaging the seat of theseal and the impulse ring of carswith ABS.

~... _( jl .-

Bearing race for inner wheelbearing

3.Separate brake disk and wheelhub. Heat wheel hub to 120-150C.

a40 - 32 Disassembling and Assembling Printed in GermanyWheel Bearing


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a

a

928 Front Wheel Suspension 404b.86 models onward: place driftin each of the grooves in turnand drive bearing races out ofhub.

Note:The bearing race for the innerwheel bearing can be pressed outusing P 85 and 9154 as before (carsearlier than 86).

2b.86 models onward: place theouter bearing race in the wheelhub and press in until seatedwith suitable pressure piece,e.g. VW 432.

Assembling3. Position inner bearing race andpress in until seated withpressure piece 9154 and pressureplate VW 447 i. Place VW 511beneath wheel hub as support.

l.Heat wheel hub to 120-15O'C.

2a.Install outer bearing race and(cars earlier than end of 85)press in until seated withpressure piece 9154.



46/458

40 Front Wheel Suspension 9284.Press in radial seal until flush 6.Tighten cap bolt of clamping nutto 15 Nm (11 ftlb), withoutturning the clamping nut.with hub.

PV-~

5.Adjust front wheel bearing,noting the following points:Tighten clamping nut slightly,turning the hub. Slacken clampingnut until the thrust washer canjust be moved with a screwdriverunder finger pressure. Do not usehub as a lever for screwdriver.

7.Recheck setting by moving thrustwasher, readjust if necessary.

a

40 - 34 Disassembling and Assembling Printed in GermanyWheel Bearing


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928 Front Wheel Suspension 40TOOLS

No.

3

+-$I> .?,/ 3Description

Press-out toolTensioning deviceTensioiyng device

Sickle wrenchDIN 1810 dia. 80/90

Special Tools

VW 267 aVW 340

Remarks

Porche version manu-factured by Klann,desription/suppliersee Workshop Manual(Workshop Equipment3, Group 4).Commercially avail-able, e.g. Saltus

0Printed in Germany - XIII, 1986 Removing and Installing 40 - 35Spring StrutDisassembling and AssemblingSnrina Strut


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40 Front Wheel Suspension 928REMOVING AND INSTALLING SPRINGSTRUT

Removingl.Working from engine compartment,remove three self-locking nuts onwheel arch.

Z.Remove wheel, unscrew flangelock nut and press off upperball joint with VW 267 a

3.Unscrew self-locking nuts fromupper control arm (inside enginecompartment).

4.Remove damper mounting bolt.

Installing

Renew all self-locking nuts. Coat arubber bush in mounting eye withMolykote U.

a40 - 36 Removing and Installing Spring Strut Printed in Germany


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- I7 -4/WYa - /9 I_ 54 ! -! -YaEuD-I-.

!I

4zmps.p* - -

11

Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 37Non-Adjustable Spring Strut


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40 Front Wheel Suspension 928No. Description

1* Self-locking hexnut

2* Washer

3* Damper mounting,upper

4 Spring plate,upper

5 Coil spring

6 Protective tube

7** Booster spring

8* Stop washer

9*

10

11

Supporting cover

Spring plate,lower

Damper

RY.

1

2

1

1

1

1

1

1

1

1

1

Note When:Removing

Extend coil springwith VW 340 orKlann KL - 0014

Mark installation Install right wayposition round

Installing

Renew and tighten to60 Nm (44 ftlb)

Coat rubber bushdith Molykote U

Note arrangement andassembly instructions

Overall lengthapprox. 170 mm

Note installationposition

Install with groovesdown

Boge only

Check efficiency,renew if necessary.Standard:Boge (black)**Optional:Bilstein (green)* Same parts as those used in adjustable spring strut** Same parts as those used in adjustable spring struts earlier thanend of model year 1985

40 - 38 Disassembling and Assembling Non- Printed in GermanyAdjustable Spring Strut


51/458


r---1

6

c.7 -_

-6----- -49

:!i

g 1L

-?r

ll-12-

IIIIIIiii!IIIIIi

M* -y>-24-qP- e-y-3i m , 2

t ib -4w .gF

-_c.r -7

13

a 2 Stop washers No. 8 in 928 S 4 "Club Sport-Version"

Printed in Germany - XX, 1988 Disassembling and Assembling 40 - 39Adjustab le Spring Strut


52/458

40 Front Wheel Suspension 928No. Description Qty1*

2*

:*

6

7

a*

9*

1C

Self-locking hexnut

Washer

Damper mounting,upper

Spring plate,upper

Ceil spring

Protective tube

Booster spring, upto end of Mod. yr.85* natural color(35 mm springtravel) 86 modelsonward black (39mm spring travel)

Stop washer

Supporting cover

Spring plate,lower

1

2

1

1

1

1

1

:A

1

1

Note When:Removing

Extend coil springwith VW 340 orKlann KL-0014

lark installationlosition

* Same parts as used in non-adjustable spring strut.

Installing

Renew and tighten to60 Nm (44 ftlb)

Coat rubber bushwith Molykote U

Note arrangement,tolerance group andassembly instruc-tions. Differentspring rates (springhardness)

Overall lengthapprox. 150 mm

Note installationposition

Install with groovesdown,2 washers in 928S4 "Club Sport Version"Boge only

Install right wayround.Boge: blackBilstein: yellow

a40 - 40 Disassembling and Assembling XX,1988 - Printed in GermanyAdjustable Spring Strut


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928 Front Wheel Suspension 40No.

11

12

a13

Description

Adjustment nut

Threaded ring

Damper

QtY.-1

1

1

1emoving Note When: Installing

Grease thread, re-cess and contactsurface for springplate with DptimolyTABoge and Bilsteinare different

Boge only.Install with innerbevel down.Coat thread withOptimoly TA

Damper design modi-fied, 86 modelsonwardDamper installationoverview P. 40 - 51Spring installationoverview, noteP. 40 - 46

Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 41Adjustable Spring Strut


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40 Front Wheel Suspension 928NOTES ON DISASSEMBLY AND ASSEMBLY

Disassembling VW 340

l.Mark position of lower springplate relative to damper forreinstallation.

r-

2.Using Porche version Klann springtensioning device (see WorkshopManual) or VW 340, extend coilspring.Remove self-locking nut frompiston rod.Remove washer and upper dampermounting.

_--.-g-JJf \ ,1

) ~.-ST 4 _-4.,1 : -J-y $.-. ..+

,)L .-..r.c., 1LJ~~~~~ i j(0

KL - 0014 (Klann),. \jy ,

I z Ic -(d:-:Ti-;-; .--&

91 y=rI; c.F - _ \

"g-y+~~!yzri=/ -c:-==zT, 'IlilCq&N'-3xgzrA. r

3.When using special tool VW 340,release coil spring by unscrewingeach of the expansion bolts inturn.

Note:A great deal of caution is requiredwhen working with the extremelypowerful coil spring.

t! i -40 - 42 Disassembling and Assembling Printed in GermanyAdjustable and Non-Adjustab leSpring Struts


55/458

928 Front Wheel Suspension 40Testing DampersDampers can only be tested properlyon a testing machine. Dampers whichno longer perform adequately cannotbe identified by visual inspectionor function testing, which will,however, identify completelydefective units.

Note:Differences between dampers, P.40 - 51

Boge PressurelessDamperWith damper in installation posi-tion, extend and compress by hand.The damper must move smoothly andwith uniform resistance throughoutits travel. The extension and com-pression stage damping must beclearly perceptible up to the limitpositions. Dampers which have beenstored for an extended periodshould be operated several times intheir installation oosition. Renewleaking dampers

Boge Gas-pressDampers

ure

With damper in installationposition, extend and compress byhand. The damper must move smoothlythroughout its travel. Theexpansion and compression stagedamping must be clearly perceptibleup to the final position.

Because of the gas pressure, resis-tance increases as the piston rodmoves further into the damper.Dampers which have been stored forlengthy periods should be operatedseveral times in their installationposition.Renew leaky dampers.Dampers in which the gas pressurehas diminished (damper does notreturn automatically to theextension-stage stop), but whichbear no indication of oily leaksand which fulfill all otherrequirements can be reused.Dampers which show traces of oilloss and which have depressurizedmust be renewed.

Bilstein DampersWornBilstein Damperscan be identified with ease.Measure distance X with dam perfully compressed (i.e. as far aspossible). If distance X exceeds35 mm (29.5 mm when new), thedamper must be replaced.

Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 43Adjustable and Non-AdjustableSpring Struts


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40 Front Wheel Suspension 928Assembling N o t e (for information only)l.Note arrangement of coil springs. During original assembly of theSee P. 40 - 46 for adjustable struts, the adjuster nut is mounted

spring strut. as follows:See pp. 40 - 47 to 40 - 49 fornon-adjustable spring struts.End of coil spring points towardupper spring plate.

Boge spring strut: threaded ringflush with adjuster nut at top(arrow) or threaded ring approx.5 nun lower.Bilstein strut: adjuster nutscrewed down to bottom.

--/- -_.*W&_.

2.If parts which affect the heightsetting of adjustable springstruts have been replaced, beginby moving the adjuster nut to itsoriginal position. After instal-lation, readjust height settingas necessary, see Item 5. Lubri-cate threaded ring or thread andadjuster nut and recess withOptimoly TA.

3.To avoid dislocation of the lowerspring plate of non-adjustablespring struts, only 2 spacers maybe used per strut for height ad-justment. When converting fromBilstein to Boge dampers(pressureless), the white/greenspring can be reused if a spaceris installed (P. 40 - 47 to40 - 49).

40 - 44 Disassembling and Assembling Printed in GermanyAdjustable and Non-AdjustableSpring Struts


57/458


4.Because of the 14" offset ofupper spring plate to mountingeye (of control arm) when thestrut is installed, it may benecessary to determine theposition of the lower springplate as follows when the strutis assembled:

Mount upper spring plate on car.With lower spring plate and coilspring at damper installationposition, set damper on lowercontrol arm.Move end of coil spring to upperspring plate stop. Turn lowerspring plate until the springtouches the lower stop as well.Mark position of lower springolate to damoer. Assemble strutsas marked.

N ote:Adjustable spring struts can alsobe brought to their installationpositions by turning the adjusternut (hold strut at bottom ). Turnnut in the direction which allowsend of spring to remain againstspring-plate stop.

If a Klann spring tensioner isused (no vise required) the strutcan be brought to its instal-lation position with the springpre-tensioned. Screw self-lockingnut onto piston rod (risk ofaccident).

5.Adjust height setting of adjus-table spring struts asneccessary.

Note:

Moving the adjuster nut (springpre-load) through 5 mm adjusts thevertical setting by approx. 10 mm.In this context, note thefollowing:Any one-sided height adjustmentalso changes the wheel loadina.When the ioad on any one wheel ischanged the loads on the otherwheels also change.If no wheel-load mete r isavailable, the 2 height adjusternuts on a comm on axle should bechanged by the same amount to keepthe wheel- load difference fromleft to right within permissiblelimits. (Difference from left toright per axle, max. 20 kg).

Printed in Germany - XIII, 1986 Disassembling and Assembling 40 - 45Adjustable and Non-AdjustableSpring Struts


58/458

40 Front Wheel Suspension 928COIL SPRINGS FOR ADJUSTABLE SPRING STRUTS

Two types of front-axle sprin s are available. The springs have differentspring rates (spring hardness 7 . The springs are color-coded.

The springs with green and brown codes are subdivided in tolerance groups.

When repairs are carried out, always install springs with the same colorcode. As the vehicle height can be adjusted, it is not necessary to selectspring groups to suit certain models (e.g. left-hand or right-hand drive).

Coil Spring Part No. 928 343 511 06 (green)Used in: 928 S with ressureless Boge dampers from September 1983 to endbf model year928 S with Bilstein dampers from February 1984 onward.

Group

:3

Color code

1 x green2 x green3 x green

Spring force F where Orderinglength LI = 191 mm index6377 - 6573 N6574 - 6769 N6770 - 6965 N

201202203

Free length(new springs)

approx. 350 mmapprox. 350 napprox. 350 mm

Coil Spring Part No. 928 343 511 09 (brown)

Used in: 928 S with Boge gas-pressure dampers as standard and optionalextra (soort)- 86 models onward

Group

1*23

Color code

1 x brown*2 x brown3 x brownt

Spring force F where Ordering Free lengthlength LI = 191 mn index (new springs)

6375 - 6570 N6571 - 6766 N6767 - 6963 N401402403

approx. 340 mmapprox. 340 mmapprox. 340 mm

40 - 46 Coil Springs for Adjustable Printed in GermanySpring Struts


59/458


COIL SPRINGS FOR NON-ADJUSTABLE SPRING STRUTS

Three types of front-axle springs are available. The different types arecolor-coded - blue, white, white/green.The springs with blue and white coding are subdivided in tolerance groups.

When repairs are carried out, always install springs with the same colorcoding. As the car tends to settle in the course of its service life andinstallation of a single spring could upset the vehicle height, werecommend replacement in pairs.

Coil Spring Part No. 928.343.511.01 (blue)

Used in: 928/982 S with Boge dampersAs of start of range up to following chassis numbers:92 A0 80 0645 928 Europe/rest of the world/Japan92 A0 81 0714 928 USA92 A0 82 0127 928 S

Group

1

Color code Installed in Spring force F wherelength LI = 217 mm

1 x blue Vehicles 6377...6573 Nwithout airconditioner301

2 x blue Vehicles with 6574 . ..6769 N 3023 x blue air conditioner 6770...6965 N 303

Orderingindex

For a brief period, group 1 springs with spacers were installed in vehiclesequipped with air conditioners.Group 2 and 3 springs without spacers can be installed in these vehicles.

Printed in Germany - XIII, 1986 Coil Springs for Non-Adjustable 40 - 47Spring Struts


60/458

40 Front Wheel Suspension 928Coil Spring Part No. 928.343.511.03 (white)Used in: 928/928 S with Boge dampers

as of following chassis numbers:92 A0 80 0646 928 Europe/rest of the world/Japan92 A0 81 0715 928 USA92 A0 82 0128 928 S

Group Color code

: 1 x white2 x white

Installed in Spring force F wherelength L1 = 211 mm s,r;E;ing

L-H drive cars 6377...6573 N 901R-H drive cars 6574...6769 N 902

Group 1 springs with spacers have also been installed in right-hand drivecars. Refer to table when replacing.Springs with 3 white dots (discontinued) were installed in a small numberof cars. Use group 2 springs as replacements.

Coil Spring Part No. 928.343.511.04 (white/green)

Used in: 928/928 S with Bilstein dampers for all cars.

Group Color code Installed in Spring force F where Orderinglength Ll = 205 mm index

1 1 x white/ all cars 6377 . ..6630 N nonegreen

40 - 48 Coil Springs for Non-Adjustable Spring Printed in GermanyStruts


61/458


Effect on Height of Front Axle

1.

2.

Front Axle SpringsSprings with approx. 200 N more forcetolerance group II springs as opposedthe front axle by approx. 5 - 15 mm.

Spacer

at a standard test length (e.g.to group I) increase the height of

Placing a spacer beneath the lower spring plate increases the height ofthe front axle by approx. 10 mm. A maximum of 2 spacers per spring strutis permissible.

,g +sp-F? ,.awI- - - -; w,,

M -.

3.Gas-pressure Dampers (Bilstein)If Boge dampers are replaced by Bilstein dampers and no further changesimplemented, i.e. the same coil springs are reused, the front axle israised by approx. 10 mm because of the gas pressure in the latterdampers. We recommend use of springs Part No. 928.343.511.04 in con-junction with the gas-pressure dampers.

Printed in Germany - XIII, 1986 Coil Springs for Non-Adjustable 40 - 49Struts/Effect on Car Height


62/458


aDAMPERS - INSTALLATION OVERVIEW, IDENTIFICATION AND DISTINGUISHING FEATURES

IFront axle

Rear axleISinole oioeOC

Non-adjustable front-axle spring strut9281928 S X X

a standard 101 109281928 S x xoptional extra 0 0Adjustable front-axle spring strut928 S standard X Xuntil end of model 0 0year 85928 S optional x xextra until end of 0 0model year 85928 S standard X X86 models onward 0 0

a 928 S optional extra X X86 models onward 0 0alternative x x

)ie pipe'ressurelessJGas pressure

x x0 0x xx0 0x xx0 0

v-vgreyreyrededrededgoldoldgoldold

BogeBilsteinPaint coding,Identification

( x black*1 0 black**

x x green0 0 green

x x0 0 goldgold

*/** Identical partsNote:Optional Extra = Sport TuningWhen removed, the pressureless damper will remain in any desired position.When the gas pressure damper is removed it extends to the expansion stagestop.

aPrinted in Germany - XIII, 1986 Dampers - Installation Overview 40 - 51


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928 Rear wheel, suspension proPshaft 42Technical DataRear AxleWheel suspension

DampersMake/InstallationStabilizers

lSpacers

Independent wheel suspension with lower diagonal suspensionlinks and upper wishbones, coil springs and internal dampers.

1 coil spring per wheeldouble-action hydraulic damperspage 42 - 18 d021 mm0 22.5 x 3.5 mm (tubular stabilizers)modified in course of model year 1981standard up to end of MY 91Club-Sport-Versionstandard as of MY 92

______.-________-____17 mm per wheel38 mm per Rad

l Technlcal Data 42 - 01Printed in Germany -XXIX. 1992


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42 Rear Wheel Suspension, Propshaft 928TIGHTENING TORQUES FOR REAR AXLE

Location Description Thread

Tranverse member tobody Hex bolt

Light alloy casting(suspension linkbearing) for lowercontrol arm (86models onward) tobody

Hex bolt

Lower suspension linkto transverse member(camber eccentric)Locknut

Lower suspension linkto body or light-allo:casting (trackeccentric)

Locknut

Bearing link to lowersuspension link Locknut

Brake caliper towheel carrier Hex bolt

Wheel carrier to lowe)suspension link Locknut

Upper suspension linkto transverse member,upper suspension linkto wheel carrier

Locknut

Propshaft or rearaxle to wheel hub

Locknut

Propshaft to differ-ential and input shaftWheel to wheel hub

Cap bolt

Wheel nutSpring strut to body Locknut

M 10

M 10

VNM14 x

VNM12 x

VNM

.5

1

12 x 1.5Y 12 x 1.5

VNM14 x 1.5VNM 10

VHM22 x 1.54 10

1 14 x 1.5/NM 10

Material

10

10

8

8.8

8

B

3

12.9

\L3

i

Torque Nm(ftlb)

46 (33)

46 (33)

200 (146) a

120 (88)

85 (62)

85 (62)

140 (103)

46 (33)0

460 (322)

81 (59)

130 (94)46 (33)

42 - 02 Tightening Torques Printed in Germany


65/458

928 Rear Wheel Suspension, Propshaft 42Location

Rubber bushing onpiston rod (springstrut)Transmission bearingto rear-axle trans-verse memberStabilizer bearing tobodyStabilizer linkage tolower suspension linkStabilizer linkage tostabilizerSpeed sensor to wheelcarrierAngle bracket to wheelcarrierAngle bracket totransverse memberGuard to wheel carrier

Description

Locknut

Hex bolt

Hex bolt

Hex bolt

Locknut

Cap bolt

Hex bolt

Locknut

LocknutHex bolt

Thread

VNM12 x 1.5M 12 x 1.5

M 10

8

8.8

8.8M 10 8.8VNM 10

M6

a8.8

M6 8.8VM 6

VEM 8 8M6 8.8

Material Torque Nm(ftlb)

58 (42)

85 (62)

46 (33)46 (33)46 (33)

10 (7)10 (7)6 (4)

Printed in Germany - XIII, 1986 Tightening Torques 42 - 03


66/458

923 Rear Wheel Suspension. Axle Shaft 42TOOLS

V. Description Special Tool Remarks

1 Punch I\ 407Thrust plate VW 402

3 Tube VI\ 41s a4 Punch Vii 408 a5 Support ring 1% 4406 Thrust tube h ,155I Remover/installer VW 459/2 Part of VW 4598 Tllrust tube P 2M

Prmred in Germany IIirasrer~~blin~ and Aswn,hling Rear Suspension 42 - 1


67/458

RCBI Wheel Suspension. Axle Shaft

1210 71,:

:ln ?Yf- I9

] m-r

--b

[ ,*

-.27 / -1&j-i 3 ,yI_ .,,,,,j ,$ &p-z: :b 23 *A .? T+n 2,

~24-~40~31 ~A 4 32

30382928

-1 2

42 - 2 I,i5ascnhlinc 3nd ,Asscnlhlins licar Surpnciiin Primmed in Germany


68/458

928 Rear Wheel Suspens ion, Axle Shaft 4240. Description

1 Self-locking nut

w. Note When SpecialRemoving Installing Instructions

1 Replace if necessary.Tighten to specifiedtorque

2 Washer 13 socket head bolt 6 Tighten to specifiedtorque4 Axle shaft 1 Check for damage5 Locknut 3 Replace. tighten to

specified torque6 Warhei 737 Plug 1a cover 19 Locknut 2 Rrplace. tighten to

specified torque10 Washer 211 Pivot pin 1I2 Washer 113 cone washer 214 Spring strut 1 If necesrary. replace

seal on mountingplate

15 Locknut 2 Replace, tighren 10specified torque

LG Cone washer 111 Bolt 118 Cone washer 219 Hub assembly 1 Straighrening not

permitted20 Boll 1

l Printed in Germany VII, l!i83 Disassembling and Assembling [icar Suspension 42. 3


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42 Rear Wheel Suspension, Axle Shaft 928Note When: Special

NO. Description my. Removing Installing Instructions21 upper control arm 1 Straightening not

permitted22 upper arm mount 2 Position correctly23 Bolt 1 Tighten to specifiedtorque24 Washer 225 Locknut 1 Replace and tightento specified torque26 Bolt 1

27 Stabilizer suspension 1 Check for damage page 42 626 Locknut 1 Tighten to specifiedtOrqe29 Eccentric disc 130 Eccentric bolt 131 Locknut 1 Tighten specifiedotOrqe32 Washer 133 Eccentric bolt 1 Lubricate withMoSz greare34 Lower control arm 1 Check for damage Left and rightsides not inter-

changeable,35 Locknut welding and1 Replace and tightento specified torque straightening notpermitted36 Washer 2 Replace necessaryf37 Bolt 138 Mount 1 Position correctly39 Rubber mount 1 page42.640 Rubber mount 2 page 42 6

42.4 Disassembling and Assembling Rear Wheel Suspension VIU. 1964 Printed in Germany


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928 Rear Wheel Suspension, Propshaft 42NOTES ON DISASSEMBLY AND ASSEMBLY

Disassembling

l.Remove propshaft with driveshaft.

2.Remove brake caliper.

3.Take off brake disk afterremoving two countersunk screws.

4.Remove parking brake shoes andexpansion lever. Pull parkingbrake cable out of its guide inwheel carrier.

5.Remove wheel carrier.

Printed in Germany - XIII, 1986 Disassembling and Assembling 42 - 5Wheel Suspension

6.Unscrew eccentric bolts andstabilizer linkage bolt andremove lower diagonal suspensionlink.


71/458

42 Rear Wheel Suspension, Propshaft 928Notes on WheelSuspension, 86Models Onward.The exhaust system has beenmodified as of model year 86. Twosecondary mufflers are mounted nearthe control arms, one on each side.This modification has necessitatedmodification of the followingcomponents:

Rear axle transverse memberBearing link of lower suspensionlink mounted on a removablelight-alloy casting (instead ofdirectly on body).The length of the track eccentricbolt (2) has been changed to suitthe modified bearing (bolt shankapprox. 10 mm longer).

2.Coat shanks of camber and trackeccentric bolts with Optimoly TA(instead of multi-purpose greasewith MoS2) and coat thread withOptimoly HT. Apply a coating ofMolykote IJ to rubber bushing ofstabilizer linkage and rubberbushings No. 39 and 40 of lowercontrol arms (page 42 - 2) beforeinstalling suspensions links incar.

N

See Table of Consumables (Tech-nical Information Group X) forfurther lubrication notes andspecifications.ote:

Spray toe-in eccentrics and cambereccentrics on both sides, adjust-ment for spring plate on damper andends of bearing bolt threads (wheelcarriers) with underbody wax suchas Tectyl - UL - 846 manufacturedby Valvoline. This precaution pre-vents corrosion of the threadedconnections, thus facilitatingfuture maintenance and repair work.

3.Tighten bolts and nuts tospecified torque.

4.Align axles.

Assembling

l.Inspect parts for damage, comparesuspect parts with new parts. Donot mix up left-hand and right-hand lower diagonal suspensionlinks (otherwise spring travel isimpaired).

42 - 6 Disassembling and Assembling XIII, 1986 - Printed in GermanyWheel Suspension


72/458

a

Rear Wheel Suspension, Axle Shaft 42TOOLS

N.

IDescription

PunrhBase plateDrive sleeveTubeExtractor

ipecial Tool Remarks

VW 407VW 441VW 244 bVW 415 a

Standard

Printed in Germany Disanrvnhling and Asscmhling llub Assembly 42 - 7


73/458

42 Rear Wheel Suspension, Axle Shaft 928

pcz:, _. .-i p1

Pa

42 - 8 Disassembling and Assembling Hub Assembly Printed in Germany


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Y28 Hear WbEe.1 Suspension, Anlc Shaft 42C;ote wren SpecialI. Description WY. izelmoving Installing Instructions

1 Self-locking nut 1 Replace if necerrary,tighten to specifiedturqw

2 Washer 1:i Socket head boll 6 Tighten to specified

torque4 Axle shaft5 wthce1 hub

1 Check for damage1 Press off with Press on wit11

VW 244b and VW 244 b. wherebysuitable base ball bearing innerPM3 race must be on

VW 415 a

6 Circlip 1 Replace if necessary7 Brake backing plate 1 Insert wheel hub inball bearing before

pressing in8 Ball bearing 1 lleat hub carrier Ileat hub carrier to

to 120 - 1.500 c 120 - 150' C(248 -(248 - 302' f). 3020 Fj. Install newPress out with boring. PlaceVW415 a IV 441 underneath

hub carrier and presson lightly withVW 415 a. beingcareful that innerraces do not fallOut

3 Hub carrier 10 Gasket 1 Replace

Prinied in Germany Disassembling and Arscmbling Hub Assembly 42 - 9


75/458

42 Rear \\hccl Suspension. Aulc Shaltl,,SrASSC\,li,.,NG AN,, ASSEhliiLiSG liLI:i hSS,:Vli,.Y

Disassembling1. Prerr out rchcel hub with VII X4 b and suitable

barc pl;itL%

2. Remove circlip

4. Press hearing inner iace o ff of wheel hub withan extractor and Special Tool VW 407.

,._ - a, \pi ._-+


76/458

928 Rear Wheel Suspension. Axle Shaft 42Assembling1. Heat hub carrier to 120 - 150 C (248 - 302 F).

install ball bearing and then pres on slightly.

l VW441 -: L-L - ! me---+c-%.rAh_a-a:.At- .2. Press in wheel hub after installation of circlip

and brake backing plate.

Printed in Germany Disassembling and Assembling Hub Assembly 42 - 11


77/458

42 Rear Wheel Suspension, Axle Shaft 928REPLACING LOWER DIAGONAL CONTROL ARM LINK PIN

RemovingwJ- z,:.;!

1. Remove bolt from link pin.

2. Place lower control arm on Special Too l VW 402.Press cut link p in with Special Tool V W 407.


78/458

928 Rear Wheel Suspension, Axle Shaft 42REPLACING UPPER CONTROL ARM MOUNT

Removing Installing

Press out mount with Special Tool VW 408a. usingSpecial Tool VW 415 a as a base.

PIT--Jc-- I

I c

Press in mount, using waxfree Capella Oil BITexaco) and Special Tools VW 415 a and 408 aPosition correctly. Apply pressure pad toconical end of metal bushing to prevent anychange in position between the metal bushingand rubber mount.

;p 1. c-1-i

Printed in Germany - VI. 1982 Replacing Upper Control Arm Mount 42.13


79/458

42 Rear Wheel Suspension, Axle Shaft 928a

REMOVING AND INSTALLING SPRING STRUT

Removing1. Unscrew three self-locking nuts from

spring strut in luggage compartment.

2.

3.

4.

Remove wheel.

Unscrew front nut on pivot pin of lowercontrol arm , counterlocking and counter-holding the rear nut with a separateM 14 x 1.5 nut. Remove pivot.

Disconnect stabilizer bar link at controlarm.

Installing1. Replace self-locking nuts. Check spring

strut seal, making a new permanentlyelastic seal on the mounting plate 300mmlong and circular in shape with, forexample, Prestik 4 mm dia., Item No.0593 from Bos tik. Coat rubber mount onmounting eye with Molykote U.

2. Tighten to specified torques.

3. Note installed position of lower shockabsorber.

NoteTurn lower shock absorber to correctposition with a hook wrench applied toadjusting nut.Select direction of turning sothat stop of spring retainer remains on endof spring. Further the adjusting nut must notbe turned against the threaded sleeve, sothat the car height adjustment is notchanged.

a42-14 Removing and Installing Spring Strut VIII, 1984.Printed inGermany


80/458

928 Rear Wheel Suspension, Propshaft 42TOOLS

l No.1

2

Description

Tensioning deviceTensioiyng device

Sickle wrenchDIN 1810dia. 80/90

Special Tools

VW 340Remarks

Porsche version byKlann, see WorkshopManual (WorkshopEquipment 3, group 4)for description/supplier.

commercially available,e.g. Saltus

lPrinted in Germany - XIII, 1986 Disassembling and Assembling 42 - 15Spring Strut


81/458

42 Rear Wheel Suspension. Axle Shaft 928r --7I

13

14 ~..T-,r( - -315 i.~ J-J

16---i->

t-5,~s+-----6

6

-42 - 16 Disassembling and Assembling Spring Strut Printed in Germany


82/458

928 Rear Wheel Suspension, Propshaft 42a

No.

1

L

34

l 5

8

9l10

11

12

13

Description

Locknut

Washer

Cover

Dirtexcluder

Locknut

Washer

Mountingplate

Rubbersupport

Damperbushing

Supportplate

Spring plate

Coil spring

Protectivetube

tY-3

31

1

1

1

1

1

1

1

1

1

1

Note When:Removing

jtretch coil springrith VW 340 or Klann:L - 0014

Installing



coat with Molykote U

coat with Molykote U

see note on page42 - 18c

see note on page42 - 18cnote allocation,tolerance group andremarks on page42 - lSb/c

Printed in Germany - XIII, 1986 Disassembling and Assembling 42 - 17Spring Strut


83/458

42 Rear Wheel Suspension, Propshaft 928No-1415

16

17

18

19

20

21

Description

CirclipSecondary spring

stop

Lower springplate

Support cover

Threaded sleeve

Adjuster nut

Damper

ItY-11

1

1

11

1

1


Check installationposition

Install with groovesdown

Coat contact surfacefor adjuster nut withOptimoly TA.Note remarks on page42 - 18cBoge only

Coat thread withOptimoly TA. Seeremarks on page42 - 18cCheck freedom ofmovement (to facili-tate adjustment). Bogeand Bilstein aredifferent. See remarkson page 42 - 18c

Check efficiency,renew if necessary.Modified dampers as ofmodel year 86. Damperinstallation overview,page 40 - 18d

l42 - 18 Disassembling and Assembling Spring Strut Printed in Germany


84/458

a

928 Rear Wheel Suspension, Propshaft 42NOTES ON DISASSEMBLY AND ASSEMBLY

Disassemblingl.Using Porsche-version Klannspring tensioning device (seeWorkshop Manual) or VW 340,stretch coil spring.Remove self-locking nut from

piston rod. Remove mounting platewith support plate.

VW 340

r-.&.&g-2-~--cpk-$3


85/458

42 Rear Wheel Suspension, Propshaft 928piston rod increases as the rodmoves into the damper. If dampershave been stored for a long time,pump in and out several times ininstallation position.Replace leaky dampers.If dampers have depressurized(damper does not return automati-cally to expansion-stage and stop),but show no si ns of escaping oil(oil staidulfill theremaining requirements, they can bereused. Dampers which show tracesof oil leaks and have lost theirgas pressure must be replaced.

Bilstein DampersWorn B i 1 s t e i nd a m p e r s can be readilyidentified.Measure dimension X with dampercompletely compressed (i.e. as faras possible). If dimension X islarger than 18 mm (new damper8.5 mm), the damper must bereplaced.

AssemblingRear-axle springs are available inthree versions. The versions arecolor-coded.The springs with green, yellow andblue coding are further subdividedin tolerance groups.

When replacing, always installsprings with the same color coding.Under no circumstances may yellow,green and blue springs be combined.

As car height is adjustable, it isnot necessary to correlate springgroups with certain model types(e.g. with or without air con-ditioner, left-hand or right-handdrive).

Coil spring (green)928, until end of model year 78Part No. 928.333.531.09Gr. F where Color Order-LI = 272 mm code ingIndex

nq-!j 1 4719 . ..4817 N 1 green 201z 4818916 . ..4915.5013 N 2 greenreen 20203

l42 - 18b Disassembling and Assembling Spring Strut Printed in Germany


86/458

928 Rear Wheel Suspension, Propshaft 42Coil spring (yellow)928/928 S from 79 models untilcurrent 84 model year (see notebelow), Part No. 928.333.531.12Gr. F where L1 = Color253.5 mm I I

Ordercode index

: 4710811 . ..4810.4910 N 2 yellowellow 101023 4911 . ..5010 N 3 yellow 103

a Note:As of the following chassisnumbers:

92 ES 840 416 928 S Europe/r.o.w92 ES 849 568 928 S Japan92 ES 860 562 928 S USA

in the current 84 model year, thecoil springs, both spring plates o fthe supporting plate and the adjus-ter nut with threaded sleeve havebeen modified to reduce weight.

aCoil spring (blue)928 S, installed in the current 84models as of the chassis numberslisted above, Part No. 928.333.531.14.

Orderindex

t301302303

aPrinted in Germany - XIII, 1986 Disassembling and Assembling 42 - 18cSpring Strut


87/458

42 Rear Wheel Suspension, Propshaft 928 aDAMPERS - INSTALLATION OVERVIEW, IDENTIFICATION AND DISTINGUISHING FEATURES

Yllb UnIF

Rear axleSingle pipe

BbgeBilsteinNon-adjustable front- Paint coding,axle spring strut Identification928/928 S X xx x black*standard 0 00 0 black**928/928 S x x x x greenoptional extra 0 0 0 0 greenAdjustable front-axle spring strut928 S standard X xx x black*until end of model 0 00 0 black**year 85928 S optional x x x x goldextra until end of 0 0 0 0 goldmodel 85ear928 S standard X X x x 9rw86 models onward 0 0 00 grey928 S optional extra X X x x red86 models onward 0 0 00 redalternative x x x x gold

0 0 0 0 gold*/** Identical partsNote:Optional Extra = Sport TuningWhen removed, the pressureless damper will remain in any desired position.When the gas pressure damper is removed it extends to the expansion stagestop.

42 - 18d Damper - Installation Overview Printed in Germany

a

a

a


88/458

928 Rear Wheel Suspension, Axle Shaft 42a REMOVING AND INSTALLING AXLE SHAFTAxle Shaft Bolted on Both Sides

Removing1. Remove cylinder head bolts on transmission

and wheel ends.

2. Run out axle shaft on righthand side towardinside.

3. Run out axle shaft on lefthand side towardoutside, after removal of rear wheel. Makesure that grease from cons tant velocity jointa does not come on brake disc.

Axle Shaft Welded on One Side

Removing1. Remove socket head bolts on transmission end

and self-locking nut on wheel end.

Note:Self-locking nut is accessible after removing wheelcover.Wheels do not have to be removed.

2. Run out axle shaft on right and left sides towardinside.Lower rear end of exhaust assembly on left side.

Installing

1. Run axle shaft into wheel hub on wheel end(lubricate splines and threads with OptimolvHT).

2. Install socket head bolts on transmission end(axle shaft flange surfaces nwst not have grease).

3. Tighten socket head bolts to 83 Nm and self-locking nut to 460 Nm.

Installing

Clean axle shaft flange surfaces to remove grease.Tighten bolts to 83 Nm.

Printed in Germany VII, 1983 Removing and Installing Axle Shaft 42.19


89/458

928 Rear Wheel Suspension. Axle Shaft 42

l TOOLS

NO.

1

I234Descriprion pecial Tool

Circlip pliersPunch

VW 161 aVW 408 a

Plate.ueeYe

VW 401VW 455

Remarks

Printed in Germany _ 11, 1!)7g Disassembling and Assembling Axle Shaft 42 - 21


90/458

J ..= i:cdc \$r~~cl Suapvnsion. Arlc Sllafr !I 2x-~,. ~.-.

3 l,, (v 16. g%&j..!J!$; ,,>a~ -aI--:


91/458

928 Rear Wheel Suspension. Axle Shaft 42NO. Description Qy. Note When SpecialRemoving Installing Instrucrions

1 Circlip 2 Replace, make sureof c011ect fir

2 Constant velocity joint 2 Pack 80 grams ofgrease in each jointgroove on outsidediameter of joinrto ourside of propellershaft. Only special greaseGrease quantity only (spare part deliv-valid for joints -Y)

3 Gasket 2 Replace4 Sealing flange 2 Bearing surface must

be grease free5 Clamp6 Clamp

I DUSTboot8 Shaft

22 Cur open with lnsrall clamps betweer

side nippers machined shoulders2 Replace, if necessary1 Check r~nout

Modified Axle Shaft Dust Cover VersionsAxle shafts with welding on one side are installedsince 1082 models. The transmission end shaft isstill bolted as before, while on the wee1 end theaxle shaft and drive shaft are welded.

The welded axle shaft has a different dust coverwith improved sealing. The dust cover has a bead(arrow) and the sealing flange a groove.

Welded axle shafts con also be installed retm-actively in older models, Bolted axle shafts onboth ends. however. cannot be installed in carsafter 1982 models on (would scrape on wheel carrier). A

6

A For bolted axle shaft on both endsB For welded axle shaft on one end

Printed in Germany _ VII. 1~83 Disassembling and Assembling Axle Shaft 42 - 23


92/458

42 Rear Wheel Suspension. Axle Shaft 928DISASSEMBLING AND ASSEMBLING AXLE SHAFI

Disassembling

1. Clamp axle shaft in a vise fitted with so ftjaws.

2. Remove clamp and push dust boor with sealingflange toward inside of axle shaft.

3. Remove circlip.

4. Press off constam velociry joint using specialtools VW 401 and VW 408 a.

Assembling

1. Seal large diameter end of new dust boor withan adhesive. This requires that seats of sealingRange and boor be clean and free o f grease.Adhesive: 3 M Scotch Seal 750(available in 5 oz. tubes)

2. Squeeze new clamp with a special pliers.e.g. VW 1275. between mach ined shouldersof sealing flange.

3. i?ephce gasket on flange cOVel

4. Push dust boor with sea ling flange on to shaft.

5. Pack consranr velocity joint from each sidewith approx. 40 grams of special grease uni-formly. Total quantity of grease: 80 grams.Special grease is only for joint. Never usegrease in dust cover.80 grams of special grease is delivered witheach spare dust boor and each spare constantvelocity joint.

42- 24 Disassembling and Assembling Axle Shafr Printed in Germany


93/458

-

928 Rear Wheel Suspension, Axle Shaft 42Press constant velocity joinr on 10 shall. Install anew circlip.

Disassembling and Assembling ConsianrVelocity Join,

Primed inGermany - 11, 1979 Disassembling and Assembling Axle Shaft 42 - 25

6. Position dust boor correctly. lnsrall lamp,

Disassembling

loin1 musl be disassembled TO replace grease whenseriously conraminared or when bearing surfacesand balls have ro be inspected for wear or darnaxe

1. Swing out ball hub and ball cage fro? loinrand press our in direction of arrow.

p:. ~- k,c---&f i-

a48 -2 Removing and Installing Steering fear 1,. lR76 - Printed in Germany

porsche 928 factory manual - volume 4

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