Disassembling And Assembling Transmission G 86: Tools

Fig 1: Identifying Special Tools - Disassembling And Assembling Transmission G 86

Courtesy of PORSCHE OF NORTH AMERICA, INC.

SPECIAL TOOLS - DISASSEMBLING AND ASSEMBLING TRANSMISSION G 86

No.

Designation

Special tool

1⁽¹⁾

Puller with grip

V.A.G. 1582 V.A.G.1582/2

2⁽¹⁾

Press-in fixture

3235

3⁽¹⁾

Driver sleeve

VW 192

4⁽¹⁾

Hook

VW 681

⁽¹⁾	For explanation see Fig 1

Fig 2: Exploded View Of Transmission G 86 Components (1 Of 2)

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig 3: Exploded View Of Transmission G 86 Components (2 Of 2)

Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: If the 5th and reverse gears stick or catch after adjustment of the gear changing mechanism, before removing and disassembling the transmission first remove the lock for the 5th and reverse gears, inspect it and, if necessary, replace it. See Figure .

TRANSMISSION G 86 REFERENCE

No.

Designation

Qty.

Removal

Installation

1⁽¹⁾

Torx screw

Always replace, tightening torque 35 Nm 26 ft.lb.)

2⁽¹⁾

Guide sleeve

3⁽¹⁾

Toroidal sealing ring

Always replace

4⁽¹⁾

Shaft seal

Remove with special tool VW 681

Lightly coat the sealing lip with multipurpose grease and drive it in as far as it will go using the special tool VW 192

5⁽¹⁾

Cup spring

Small diameter (curved side) to the guide sleeve

6⁽¹⁾

Snap ring

Note the thickness for refitting (must not be mixed up). If ball bearings No. 7, the input shaft or the transmission housing are replaced, the thickness must be remeasured .

7⁽¹⁾

Ball bearing

Remove with special tools V.A.G. 1581 and V.A.G. 1582/2

Press in with special tool 3225. The open side of the plastic retainer faces the guide sleeve

8⁽¹⁾

Snap ring

As for No. 6

9⁽¹⁾

Hexagon-head bolt

Tightening torque 25 Nm (18 ft.lb)

10⁽¹⁾

Tab washer

11⁽¹⁾

Reversing light switch

Insert in correct position

12⁽¹⁾

Toroidal sealing ring

Always replace and lightly grease

13⁽¹⁾

Torx screw

Tightening torque 10 Nm (7 ft.lb)

14⁽²⁾

Torx screw

Tightening torque 25 Nm (18 ft.lb)

15⁽²⁾

Transmission case cover

Seal with Loctite 573

16⁽²⁾

Torx screw

Tightening torque 40 Nm (29 ft.lb)

17⁽²⁾

Spacer

18⁽²⁾

Torx screw

Tightening torque 40 Nm (29 ft.lb)

19⁽²⁾

Spacer

20⁽²⁾

Torx screw with collar

Tightening torque 25 Nm (18 ft.lb)

21⁽²⁾

Switch interlock

22⁽²⁾

Input shaft

23⁽²⁾

Output shaft

24⁽²⁾

Relay shaft

25⁽²⁾

Shift rod and shift fork, 3rd and 4th gears

26⁽²⁾

Interior shift rod

27⁽²⁾

Shift rod with shift fork for 1st/2nd/5th and reverse gears

Replace the shift rod for 5th and reverse gears only as a complete assembly with shift fork and driver

⁽¹⁾	For explanation see Fig 2

⁽²⁾	For explanation see Fig 3 .