M/T - Damage Analysis
911 Turbo (996)2/03 3435
Binder - 3, Manual Transmission
Analysis of Manual Transmission Damage
Date: 7-25-03
Vehicle Type:
911 Turbo (996) / 911 GT2 (996)
Model Year:
As of '01 (1)
Concern:
Damage diagnosis based on Damage Catalog on Turbo Manual transmission G96/50 (standard and I No. X50) & GT2 Manual transmission G96/88.
Information:
You will shortly receive a Damage Catalog (with Supplement 36 for the 911 Turbo (996) Technical Manual, Group 3, Repair), which will serve as the basis for assessing the affected components for the following complaints:
- scratching when shifting 1st/2nd gear,
- poor shifting of 1st/2nd gear,
- scratching when shifting 3rd to 6th gears,
- poor shifting of 3rd to 6th gears,
- noises when idling.
The damage photos in the catalog can help in the recognition of possible damage causes and in assigning them to the party responsible, e.g. assembly fault or misuse by the customer.
Warranty Info:
Damage resulting from customer misuse cannot be claimed under warranty.
Repairs:
Turbo Complaint, shifting 3rd gear.
The photos shown under Item 3 in the Damage Catalog show damages to the synchronization resulting from misuse. The damages are caused by shifting without sufficient interruption in traction (insufficient de-clutching, insufficient reduction in engine speed when shifting).
Due to the driving style of the customer and in order to avoid additional transmission repair because of a "shifting 3rd gear" problem, a steel synchronizing ring, Part Number, 928 304 211 30 can be installed for 3rd gear. This synchronizing ring has the disadvantage that the amount of force required to shift into 3rd gear is increased (loss of comfort) when the transmission is cold. If 3rd gear continues to be shifted into under "conditions of misuse", the steel synchronizing ring will also become damaged.
Please inform your customers accordingly.
Literature:
911 Turbo (996) Technical Manual, Group 3:
Manual Transmission Repair 911 Turbo (996)
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