Clutch Release Lever Shaft Bearings - Modified
89porsche06Technical Bulletin
Subject: Modified Clutch Release Lever
Shaft Bearings
Model Group
911 Carrera 3
Part Identifier Number
3040 8902
December 12, 1989
ATTENTION: Service Manager/Service Technician
This bulletin replaces Technical Bulletin Group 3, Number 8902, dated May 5, 1989, which is no longer valid.
The bearings on the clutch release lever were changed from needle bearings to friction bearings. The release lever shaft bearings in the transmission case were changed from friction bearings to needle bearings.
From production date: April 6, 1989.
Transmission Numbers:
G5001 1K 03381 G5001 2K 01159 - Limited Slip Differential
G50 Transmissions, model years 1987 through 1989, prior to the above transmission numbers should always be converted to the new version when performing transmission or clutch repairs. The old version parts are no longer available.
Required Tools and Supplies
Electric Drill Special Tool kit #9292, Porsche PN 000 721 929 20 (see Special Tool Bulletin number 8915, dated 12-12-89 for ordering instructions) Oil can with ATF Olista Longtime 3 EP, Porsche PN 000 043 024 00 1 bolt 6 mm approx. 80 mm long and 6 mm nut
Conversion Instructions
1. Engine and transmission must be removed and transmission detached from engine.
2. Remove old release lever shaft and release lever. Discard old parts.
3. Both release lever shaft bearing support bores in the transmission housing must be cut to fit the new needle bearings.
Figure 1:
- Assemble cutter (9292-1), arbor/guide (9292-2) guide piece (9292-4), spring and guide pin (9292-3) as shown in Figure 1.
- Lubricate cutter and release lever shaft support bores in transmission housing with ATF.
- Guide preassembled cutting tool into release lever shaft support bores (Figure 2).
Note: The spring should be preloaded. If necessary, install spacer (10 mm nut) between guide pin and spring. Please make sure 9292-4 is properly positioned in the housing.
- Use slow speed (approx. 500 rpm) electric drill to cut bearing support A in Figure 2.
4. Cut bearing support B in Figure 3 with guide pin (9292-3), cutter (9292-1) and arbor/guide (9292- 2) until cutter bottoms out (noticeable resistance).
Note: Make sure electric drill chuck does not contact transmission housing.
5. Deburr bearing supports and clean bell housing.
Figure 4:
6. Guide the closed bearing (8 in Figure 4) on the release lever shaft and tap bearing into support
B. Remove release lever shaft and lubricate bearing with Olista Longtime 3 EP.
7. Lubricate release lever bushings with Olista Longtime 3 EP. Insert new release lever in release bearing and use a piece of adhesive tape to hold release lever in installation position.
8. Attach transmission to engine.
9. Install both seals (6 in Figure 4) on release lever shaft. Check installed direction of seals (Figure 4). Lubricate bearing (4 in Figure 4) with Olista Longtime 3 EP and install on release lever shaft.
10. Install 6 mm nut approximately 15 mm on bolt 6x8O mm. Install bolt in threaded part of release lever shaft. Insert release lever shaft in release fork from outside. Light tapping on bolt during installation is permissable.
Remove 6 mm bolt and nut. Remove adhesive tape.
11. Fill cover (3 in Figure 4) with Olista Longtime 3 EP and install in bearing support A. Install holder and bolt (1 and 2 in Figure 4).
Labor operation for converting bearings on release lever shaft:
30 40 55 5A - 60 time units
Parts Information:
Item Description Part Number
1 Bolt N 010 287 1
2 Holder 950 116 713 02
3 Cover 950 116 725 00
4 Needle bearing (open) 999 201 339 00
5 Release lever shaft 950 116 710 04
6 Seal (two needed) 999 113 418 40
7 Release lever 950 116 086 05
8 Needle bearing (closed) 999 201 365 00