986 Group 3 Transmission-Automatic PDF

www.WorkshopManuals.co.
uk
TechnicalManual
_a-e~~~-
Technicallnformation
Contents:
Group 3
Transmission,automatic transmission
WKD 483 521
Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk
Boxster Foreword
Foreword
The workshop documentationfor the Boxster model has the designation "Boxster" Technical Manual
and contains Technical Information as well as instructions on Repairs.
The integration of the technical informationpublishedin the "Boxster"TechnicalManualwith the

descriptive matter on repairs provides the user with a complex referencework that combines into one
book associated or cross-referencedmaterial of relevanceto workshops and originating from various
information media.
The "Boxster"TechnicalManualconsists of 15 folders, subdividedinto the following Groups

0 Entire vehicle -General
0 Diagnosis,part 1 (up to Repair Group 45) .1
0 Diagnosis,part 2 (as of RepairGroup 69) .2
1 Engine,part 1 {up to RepairGroup 13) .3
1 Engine,part 2 (as of Repair Group 15) .4
2 Fuel, exhaust,engine electronics
3 Transmission,manualtransmission
3 Transmission,automatic transmission
4 Runninggear
5 Body
6 Body equipment,exterior
7 Body equipment,interior
8/ 9 Air conditioning/ Electrics
9 Circuitdiagrams, part 1 (up to and includingthe '99 model) .5
9 Circuit diagrams, part 2 (as of the '00 model) .6
*1 Thetwo folderswith Group0 are to be regardedas one folder;i.e. file the "TechnicalInformation"
noticesonlyin front of the repairdescriptionsin the folder"Group0 -Diagnosis,part 1"
(up to Repair Group 45).
*2
The second folder "Group0 -Diagnosis, part 2" (as of Repair Group 69) includesthe further
Repair Groups belongingto Group O.
*3
The two folders with Group 1 are to be regarded as one folder; i.e. file the "TechnicalInformation"
notices only in front of the repair descriptions in the folder "Group1 -Engine, part 1" (up to
Repair Group 13).
*4 Thesecond folder "Group1 -Engine, part 2" (as of Repair Group 15) includesthe furtherRepair
Groupsbelongingto Group1.
Foreword
Printed in Germany -34, October 1999 VORW.CHP

Foreword Boxster
*5 The two folders with Group 9 are to be regarded as one folder; i.e. file the "TechnicalInformation"
notices only in front of the repair descriptions in the folder "Group9 -Circuit diagrams, part 1" (up to
the '99 model).
*6
The second folder "Group9 -Circuit diagrams, part 2" (as of the '00 model) includes the further
circuit diagrams belongingto Group 9.
The"Boxster"TechnicalManualhasthe samestructurein eachfolder,with the followingbreakdownfor

all Groups:
Title page, "Boxster" Technical Manual

> Foreword
Title page: "Technical Information"

> Table of Contents,Technicalinformation
> Technical information
Title page: "Repair"

> Repair Groups: overview
> Table of Contents,repairs
> General/technical data
> Instructions on repairs
As can be seen from the breakdown,the publishedTechnicalInformationis in the front part of each
folder -numbered according to the Groups. The Table of Contentsassignedto each Group will be
periodicallyupdated.
Followingthe Technical Information,separated by a title page, the instructions on repairs -assigned

according to the Groups or broken down into Repair Groups -are included in the folder.
Theinstructionson repairswill be extendedand updatedby meansof supplements.
Note
Sheetsthat alreadyexistin the "Boxster"TechnicalManualandare updatedor revisedand thereby

exchangedby a supplement are designated"Replacement sheet".Revisions or technicalmodificationson
pagesof these replacement sheetsare identifiedfor the userwith a verticalbar at the margin.
Foreword
VORW.CHP Printed in Germany -34, October 1999

Boxster Overview of repair groups
Group 0: Entire vehicle -General 0

Maintenance 03
Group 0: Diagnosis 0
Sales check 01
On-boarddiagnosis 03
DMEdiagnosis 24
Tiptronic diagnosis 37
ABS diagnosis 45
Group 0: Diagnosis 0
Airbag diagnosis 69
Seat memory diagnosis 72
Heatingdiagnosis 80
Alarm system diagnosis 90
PCMdiagnosis 91
ParkAssistentdiagnosis 91
HBAdiagnosis 94
Group 1: Engine 1
Engine-Crankcase, suspension 10
Engine -Crankshaft, pistons 13
Group 1: Engine 1
Engine-Cylinder head,valve drive 15
Engine-Lubrication 17
Engine-Cooling 19
Group 2: Fuel, exhaust, engine electronics 2
Fuelsupply,control 20
Exhaustsystem,turbocharging 21
Fuelsystem,electronicinjection 24
Fuelsystem,K-Jetronic 25
Exhaustsystem 26
Starter,powersupply,cruisecontrol 27
Ignitionsystem 28
Group 3: Transmission, manual transmission 3
Clutch,control 30
Manualtransmission-Actuation, housing 34
Manualtransmission-Gears, shafts, intogearsh. 35
Final drive, differential,differential lock 39
Group 3: Transmission, automatic transmission 3
Torque converter 32
Automatic transmission-Actuation, housing 37
Automatic transmission-Gears, control 38
Final drive, differential,differential lock 39
.
Overview of repair groups
Printed in Germany -34, October 1999 REPGRU.CHP

Overview of repair groups Boxster
Group 4: Running gear 4

Front wheel suspension, drive shafts 40
Rear wheel suspension, drive shafts 42
Wheels, tires, suspension alignment 44
Ant~Lock Brake System (ABS) 45
Brakes -Brake mechanics 46
Brakes -Hydraulics, regulator, booster 47
Steering 48
Group 5: Body 5
Body front 50
Body center, roof, frame 51
Body rear 53
Lids, flaps 55
Door front, central locking system 57
Group 6: Body equipment, exterior 6
Slidingroof 60
Convertibletop, hardtop 61
Bumpers 63
Glazing,windowcontrol 64
Exteriorequipment 66
Interiorequipment 68
Passenger protection 69
Group 7: Body equipment, interior 7
Linings,insulation 70
Seatframes 72
Seatupholsteries, covers 74
Group 8: Air conditioning 8

Heating 80
Ventilation 85
Air conditioning 87
Auxiliaryair conditioningsystem 88
Group 9 Electrics 9
Instruments,alarm system 90
Radio,telephone,on-board computer, navigation 91
Windshieldwiper and washer system 92
Lights, lamps, switches exterior 94
Lights, lamps, switches interior, theft protection 96
Group 9: Circuit diagrams 9

Wiring (up to and includingthe '99 model) 97
Group 9: Circuit diagrams 9
Wiring(fromthe '00 model) 97
Overview of repair groups

8
REPGRU.CHP Printed in Germany -34, October 1999

Boxster Table of Contents 3
3 Transmission -Automatic transmission
3 Transmission
3 Technicaldata 3-A 1
32 Automatic clutch -Torque converter

325019 Removing and installing torque
sealing converter.
ring for torque converter. 32-A 1
32 47 19 32-A 3
37 Automatic transmission -Actuation, ass. housing
371519 Adjusting
Removing
Removing
Removing selector
and
and installing
installing
installing lever Tiptronic
cable.
deflection
selector
shiftlock support.
knob.
lever
solenoid.
transmission.
lever. cable. ...
37-A I
371515 37-A 7
3704 19 37-A 9
3708 19 37 -All
3787 19 37-A17
3760 19 37-A19
370119 37 -A21
37 02 01 Removing
Checking
Removing
Removinginneroiltube.
ChangingATFfluid andand topping
installing up multi-function
gasketATF fluid. for spur switch. gear cover. . 37-A29
37 02 55 37-A33
3764 19 37-A35
373119 37-A37
37 50 19 37 -A39
3733 19 Removing and installing sealing ring for selector shaft 37-A41
38 Automatic transmission -Gears, contrcll
38 77 19 Removing and
and installing hydraulic
sensor for control
transmission unit. input speed 38-A I
381719 38 -All
381719 Removing and
and installing
installing transmission cooler.harness.
wiring
ATF speed sensor. 38 -Al3
38 18 19 38-A15
3860 19 38 -All
3 Transmission -Automatic transmission

Printl~d in Germany -13, 1997 986TOC

3 Table of Contents Boxster
39 Final drive -Differential, differential lock
39 9055 Changingand checking transmissionoil in final drive. 39 -A I

39 0137 Disassemblingand assemblingfinal drive. 39 -A 3
39 0919 Removingand installing differential. 39 -A 7
39 2219 Removingand installing sealing ring for short flanged shaft. 39 -Al3
39 2519 Removingand installing long flanged shaft. 39 -Al7
39 2237 Removingand installing sealing ring for long flanged shaft. 39 -Al9
39 1519 Removingand installingdouble sealing ring for final drivel transm. housing 39 -A23
2 3 Transmission -Automatic transmission

986TOC Printed in Germany -13, 1997

Boxster Transmis~;ion 3
3 Technical data (Tiptronic transmission A86)
5-speed Tiptronic transmission AS6
37350001
Type Code letter Equipment Installed in Model year
A86/00 5-speed Boxster 97/98/99

A86/05 5-speed Boxster 00
3 Technical data (Tiptronic transmission A86) 3-Al

Printed in Germany -30, 1999 9863Al

Transmission Boxster
Technical data
Identification of Tiptronic transmission
37350002
There are two identification plates on the transmission.One plate is located near the ATF cooler and the
other, which can be read from underneath,is on the converter bell housing.
3 -A2 3 Technical data (Tiptronic transmission AS6)

9863A1 Printed in Germany -30, 1999

Boxster Transmission
Technical data
Note
The parts marked with (*) refer only to the
transmission A86jO5.
3 Technical data (Tiptronic transmission A86) 3 -A3

Printed in Germany -30, 1999 9863A1

Boxster Transmissicln
Technical data
1 2
283.96
1- Torqueconverter 6 -ATF drain plug

2 -Sealing ring for torque converter 7 -Transmission input speed sensor
3 -ATF filter 8 -ATF filler screw
4 -ATF pan 9 -Gasket for ATF pan
5 -Hydraulic control unit 10 -Gasket for spur gear
3 T4~chnical data (Tiptronic transmission A86) 3 -AS

Printed in Germany, 1996 9863A1

Boxster Transmission
Te(:hnical data
Tightening torques for Tiptronic transmission
Location Thread Tightening torque

Nm lftlb.}
ATF filler screw

to ATF pan M30 80 (59)
ATF drain plug

to ATF pan M16 40 (29)
ATF pan to
transmission housing M6 10 (7)
ATF strainer to hydraulic control unit M5 6 (4)
Hydrauliccontrolunitto
transmissionhousing M6 8 (6)
Sensor for transmission input

speed to hydrauliccontrol unit M6 6 (4)
Solenoidvalvesto
hydrauliccontrolunit M5 6 (4)
Sensor for transmission speed to

Multi-function
switchto
transmissionhousing M6 8 (6)
Shortflangedshaftto
differential M8 25 (18)
Cover for final drive to

Plug to
coverfor finaldrive MI8 30 (22)
Mountingsaddle for long flanged

shaft to transmission housing M8 23 (17)
Housingfor spur gear to

3 Technical data (Tiptronic transmission AS6) 3 -A7

Printed in Germany. 1996 9863Al

Boxster Automatic clutch -Torque converter
32 50 19 Removing and installing torque colnverter
Tools
32500002
Item Designation Special tool Explanation

Dowel pin (long) 9595/1
32 !50 19 Removing and installing torque converter 32 -Al


Automatic clutch -Torque converter Boxster
Notes on removal and installation
Removal 2. Fixthe converterin installationpositionwith

1. Removetransmission. specialtool 9595/1.
2. With transmission in horizontalposition,

carefullyremove the converter.
Installation
Note
Check converter hub for traces of scoring. In
the event of damage or faults, the complete
converter must be replaced.
042_97
Note
If the installed position of the converter is
incorrect, the ATF pump can be destroyed when
the transmission is flange-mountedto the engine
32500001
1. Grease the bearing pin of the converter with

Longtime 3EP (Part No. 000.043.024.00).
2. Carefullypush converter onto transmission

shaft as far as the first stop. Then press
converter by hand into the converter bell
housing and turn it until the recess in the
converter hub engages in the driver of the
impeller and the converter perceptibly slides
inward.
32 -A2 32 50 19 Removing and installing torque converter


32 47 19 Removing and installing torque-convener sealing ring
Tools
No. Designation Special tool Explanation

1 Hook VW681
2 Assemblysleeve 3295
32 47 19 Removing and installing torque-converter sealing ring 32 -A3


Automatic clutch -Torque converter Boxster
Notes on removal and Installation
Removal Installation
1. Removetransmissionand converter, 1. Replacemounting-face
ring if damaged.
2. Removesealing ring with special tool VW681.

Place the special tool directly behindthe seal-
ing lip of the sealing ring so that the mounting-
1 2 3
face ring is not damaged.
-,.
~ ~
1 -Torque converter 239 -96
238 -96 2 -Sealing ring

3 -Mounting-face ring
2. Thinlycoat circumferenceand sealing lip of

sealing ring with Vaselineand drive sealing
ring home as far as the mountingface with
special tool 3295.
8
32 -A4 32 47 19 Removing and installing torque-converter sealing ring
98632A1 Printed in Germany, 1996

Boxster Automatic~ clutch -Torque converter
240 -96
32 47 19 Removing and installing torque-converter sealing ring 32 -A5


Boxster Automatic transmission -Actuation, ass. housing
37 15 19 Removing and installing selector lever cable
401-97
1 -Selector lever cable
2 -Keylock cable
37 15 19 Removing and installing selector lever cable 37 -Al


Removing and installing selector lever cable
~
~
"' >-"":
/,
"
\~ If)
407-97
37 -A2 371519 and installing selector lever cable

98637Al Printed in Gen11any -13, 1997

"~
~\~
~
Removing
Bo;(ster Automatic transmission -Actuation, ass. housing
Removingand installing selector lever cable
Removal
Note 5. Removerear wallcover.

The selector cable must not be excessivelybent
or kinked.
1. Moveselectorleverto .p. position.
2. Detach selector lever cable at deflection lever

and at transmissionsupport.
i,':'..::\.;;.:!:!;j;:;...'.".:'."..'.""~
414-97
~'-'" 6. Removecable holder
~ff
418-97
3. Removeselector knob (see Page 37 -A9).
4. Removecentre console (see Page 68 -9).

I
I ..'~I'-:---'
'",.
.~.7.. 1
-2
Ii; .
1 -Selector lever cable 408-97

2 -B+ cable
37 15 19 Removing and installing selector lever cable 37 -A3

Prinlted in Germany -13, 1997 98637Al

:~~
Automatic transmission -Actuation, ass. housing Boxster
7. Disengagingselector lever cable: Installation

1. Routethe selector lever cable (1) through
-Slide the locking sleeve of the adjuster (1)
the rear wall to the correct position on the
forward and turn it clockwise to removal
transmissionand fasten on the transmission
position.
-Press the retaining clip (2) together and

carefully pull the cable upward out of the
support bracket.
8. Press out locking piece and remove

selector lever cable. Take care not to
soil the passengercompartment.
~ \/ -\ ' ~~I
r,r /
415-97
'" , '. 2. Insert locking piece in the rear wall and fit
rear waWcover.
~\ ,''. 3. Fastencable on support bracket (2).

\ ~,..
,,;:-,- '.N1~:
,\ '-'" '"' ..,#'
4. Fitcableholder,
404-97
"-"i."'; ~'~
';~
..,.,,-:.:~
.,. .
-./
:t~?;.
-'. ,
I
r-
-., ,
:~~:
.~ :.~":;';}..:
'. ~!'I'
1 -Selector lever cable 408-97

2 -B+ cable
37 -A4 371519 Removing and installing selector lever cable

98637Al Printed in Gennany -13, 1997

5. Move selector lever and transmissionto

position "POI.
6. Press cable into the open adjuster (1) and

close the adjuster (3).
The locking sleeve must move to the end
position automatically.
7. Check adjustment of the selector lever cable

(see Page 37 -A7).
37 15 19 Removing and installing selector lever cable 37 -AS

37' 15 15 Adjusting selector lever cable
1. Move selector lever and transmissionselector

shaft to position "P",
2. Adjust cable length at mounting head so that

the cable can be fitted free of tension.
417-97
3. Check adjustment. To do this, select all gears

and check that the gear is indicated in the
right-handinstrumentcluster. Also change
gate from "D"to "M", A straight movement
must be possible without catching.
37 15 15 Adjusting selector lever cable 37 -A7


37 04 19 Removingand installing selector knob
Note
In vehicles manufacturedbefore 21.1.1997, 2. Removethe compression spring and spring

the selector knob is only pushed on and can be clip and pull off the selector knob.
pulled off by hand (important: observe Technical
Informationnotice 3d/96).
As from 22.1.1997, Porsche has been

installing a new gear selection actuator as
standard, in which the selector knob is fixed in 2
installationposition with a spring clip.
1
Removal
1. Lever off locking button with an angledpipe.
The locking button must be pressed so that
the pipe section can be inserted betweenthe
shift lever and the locking button. To do this,
turn the ignition key to "1" position.
1 -Compression spring 086_97
(conical as of 12.10.98)
2 -Spring clip
Installation
1. Assemblethe selector knob with spring clip,
compressionspring and locking button.
Note
Fit conical compressionspring with the small

diameter facing the guide peg.
2. Press the complete selector knob onto the

085_97
shift lever until it bottoms and check function
of the locking button.
37 04 19 Removing and installing selector knob 37 -A9

Printl~d in Germany. 30, 1999 98637A1
Boxster Automatic transmission -Actuation, ass. housing 37
37 08 19 Removing and installing selector support
re9-97
37 08 19 Removing and installing selector support 37 -All


Removing and installing selector support
'-..
'"
(
,\ '- 11
8
431-97
37 -A12~ 37 08 19 Removing and installing selector support

98637Al Printed in Germany -13, 1997

~
"~
1 -Cable nipple
2 -Keylock lever
3 -Adjuster
4 -Retaining clip
5 -Cable sleeve
6 -Selector support
7 -Locking button
A = Close adjuster
8 = Open adjuster
8 -Adjuster (open)
9 -Adjuster (closed)
10 -Retaining clip
II-Hexagon nut
12 -Selector lever until 21.1.1997
13 -Selector lever after 22.1.1997

(with spring clip)
37 08 19 Removing and installing selector support 37 -A13

Prinlted in Germany -13, 1997 98637Al

Removing and installing selector support
Removal
1. Removeselector knob (see Page 37 -A9). 6. Disconnect
plugconnection.
2. Removecentre console (see Page 68 -9).
3. Move selector lever to position "0",
4. Disengaging
keylockcable:
-Open adjuster (3) by pressing the unlocking

button (7).
-Press the retaining clip (4) together and

carefully pull the adjuster (3) upward out of
the support bracket.
-Disengage cable nipple (1) on the keylock

406-97
lever (2).
7. Unscrewfasteningnuts(11).
5. Disengaging
selectorlevercable:
-Slide the locking sleeve of the adjuster

forward and turn it clockwise to removal Installation
position (8).
Install in reverse order, observingthe following
-Press the retaining clip (10) together and points:
carefully pull the cable upward out of the
1. Tightenfastening nuts (II) to 10 Nm (7.5
support bracket.
ftlb.).
2. Fasteningselector lever cable:
-Press the cable into the support bracket

until the retaining clip engages in the
housing(10).
-Press cable into the open adjuster (8)

and close the adjuster(9). The locking
sleeve must move to the end position
automatically(9).
37 -A14 37 08 19 Removing and installing selector support

98637Al Printed in Gennany -13, 1997

3. Fasteningkeylock cable: 5. Removeselector lever again.
Note 6. Fit rotary valve in correct position and install

centre console.
The keylock cable should only be adjusted when
the selector lever is fitted.
-Install selector knob (refer to Service

No. 3704 19).
Turn ignition key to position "1" (ignitionon)

and move selector lever to position "0",
-Open adjuster (3).
Engage cable nipple (1) on the keylock

lever (2).
Press housingfor adjuster (3) into the

support bracket until the retainingclip (4)
engages.
Move selector lever to position "P"and turn 1 -Rotary valve 541_97
ignition key to position "0" (removalposition). 2 -Spring

3 -Direction of travel
-Press cable sleeve (5) toward the selector
support.
Releasecable and press locking button (7)

until it engages.
4. Checkkeylockfunction:
Turn ignition key to position "I" (ignition on).
Move selector lever from position "P"to "0"

and turn ignition key counter-clockwise.The
removal position must not be reached.
Releaseignition key again and engage se-

lector lever position UP".In this position, it
must be possible to remove the ignition key
and the locking button must be locked.
37 08 19 Removing and installing selector support 37 -A15


3~r 87 19 Removingand installing shiftlock solenoid
Removal
1. Removecentre console (see Page 68 -9). 5. Pull solenoid holding clip only far enough away
to permit the solenoid can be removed.
2. Removingand installing selector support Do not overstretch the holdingclip.
(see Page 37 -All).
3. Removecover plate on selector lever support.
4. Pulloff cableon manualswitch,unclipholder

for plugconnectionandremovecablefrom
the cableguides.
\. \ r-.
\.-
~
~
~~ 421-97
~I ~ Installation
1. Fit solenoid in correct position and properly
route cable underneaththe cable guides (see
420-97
figure at left).
1 -Cover plate
2 -Holder for plug connection
2. Plug cable onto manualswitch according to
the wiring diagram and fasten plug connection
with holder on the selector support.
37 87 19 Removing and installing shiftlock solenoid 37 -AI7


~
37' 60 19 Removing and installing deflection lever
"'1~ .J;:1::I
2
--
$- A
1 -Deflection lever 416-97

2 -Push rod
37 60 19 Removing and installing deflection lever 37 -A19
.

1
Removing and installing deflection lever
1. Detach selector lever cable at deflection lever 1. Lubricate deflection lever axle and bushings
with OptimolyTA (availablefrom Porsche
Parts Service).
2. Install deflection lever and fit snap ring.
3. Clip in push rod and press selector lever

cable onto axle of the deflection lever as far
as it will go.
4. Check adjustmentof the selector lever

cable (see Page 37 -A7).
417-97
2. Unclip push rod on transmission lever.
3. Remove snap ring for deflection lever and

remove lever with push rod.
419-97
37 -A20 37 60 19 Removing and installing deflection lever

98637Al Printed in Gemlany -13, 1997

BO:Kster Automatic transmission -Ac:tuation, ass. housing
37 01 19 Removing and installing Tiptronic transmission
Tools
5
3 d
336-96g

Support 10-222A
2 Support feet 9591/1
3 Assembly aid 9596
4 Dowel pin 9595
5 Hose clamp 3094
37 01 19 Removing and installing Tiptronic transmission 37 -A21

Printed in Germany Purchased
-13,
1997 from www.WorkshopManuals.co.uk
98637A21
37 Automatic transmission -Actuation, ass. housing Boxster
Removill1gand installing Tiptronic transmission
Removal
1. Disconnect
battery.
2. Removestarter
(see Repair Group 27),
3. Remove rear wall cover in passenger

compartment.
4. Fix crankshaftwith special tool 9595. To do

this, turn crankshaftuntil one of the bores U4,
U5 or U6 in the pulley is aligned with the
centring bore in the crankcase and special 152-96
tool 9595 (short) can be inserted.
9595
-.;:
-',NJ
"'\
042-97
151-96
5. With special tool 9595 (long), hold converter

in installationposition.
Note
If the special tool cannot be inserted, the cranks-
haft was not fixed properly. Check Step 4.
37 -A2~~ 37 01 19 Removing and installing Tiptronic transmission


~::
6. Install special tool 9596 and unscrewtwo of / Ii

the six converter fastening screws with a /"]"X ~I
_II A
6-mm Allen socket insert (long).
'"~
'/
.-J
y ,,8 j
352-96
8. Hold engine in installedposition with special

tools 10 -222A and 9591/1 at transport
shackle.
152-96
Note
For the remainingfour fastening screws, remove
special tool 9595, rotate crankshaftthrough a
further 1200 in each case (to pulley marking U4,
U5 or U6) and fix again.
7. Pull off vacuum pipe (B) at switch-overvalve.
194-96
9. Removediagonal braces and cross-member

panel.
10. Removestabilizer.
11. Removesilencerswith catalyticconverters.
12. Removerear cross member (V-brace).

~
1
~!
~
13. Removefront cross member. 17. Relievespring-bandclamps and pull off

coolant hoses on flow and return sides.
14. Uncouple drive shafts on the transmission
side and protect shafts from damage
(use pieces of hose with a diameter of
approximately 30 mm).
15. Clamp shut coolant hoses (flow and return

~~)
~\
sides)with special tool 3094.
\\ \ ~ l
)
.~
~
;;?'\ \
348-96
, _\l
1U "-"'
"'" /
319-96
/
/~
/
II
349-96
18. Disconnect
plugconnectionfor multi-function
switch.
325.96
16. Place oil collection tray under the

transmission.
37 -A24 37 01 19 Removing and installing Tiptronic transmission

98637A21 Printed in Germany -13. 1997

'f~
~
BO:Kster Automatic transmission -A<:tuation, ass. housing
19. Disconnectplug from transmissionsocket. Note

To do this, turn plug anticlockwiseand pull
Fastening nut "COO
(M12) must not be loosened.
off.
Otherwise, the transmission prop will be
damaged.
L ...~I
-::"~
.'-
':---
I
/
"'" ~
I~ -"""""""1
~/
II,,:=:::< :/
c
350-96
435-97
20. Detach selector lever cable at deflection A -Transmission support
lever and at transmissionsupport. B -Hydraulic mount
C -Fastening nut M12
418-97
21. Placetransmissionjack underthe

transmissionandfastenfixingstrap.
22. Removetransmission support with left and

right hydraulicmounts.

Prinlted in Germany -13, 1997 98637A21

l~
23. Unscrewtransmission/enginefastening 2. Fixinstalledpositionof converterwith special

screws. tool 9595 (long).
For screwNo.5, use polygonwrench
(10 mm, part no. 999.571.052.02),
9595
1,~- ..~
~::::= -I
-)"rJ]
3
',,'
~ "'\
042-97
'"
3. Carefullyinsert transmissionand fasten to en-
: 4,
-'-T "--'-"~.'I\ .. gine.
351.96
1,~ -."---:;~:::;:;~
~ -
24. Pull transmission to the rear and lower it -2-:=- I
carefully.
"C:::Y
3 ~
Installation
Install in the reverse order,
1. Ensureperfectseatingof dowelsleevesin
~
crankcase. ""
~, ,~
i',,"-,-;-F=-=
351-96
37 -A26i 37 01 19 Removing and installing Tiptronic transmission


~
1/)
,.:::
~
Bo)[ster Automatic transmission -Actuation, ass. housing
II! ~I
A
I
/'11/
J
~
'\ .".
/'
352-96
A -from vacuumreservoir
B -to the flat-basevalve on the transmission
Hexagon nut
10 mm multiple-toofunut
7. Check selector lever cable adjustment
With washer
(see Page 37 -A7).
4. Install transmission supports with right und left 8. Check coolant level (see RepairGroup 19).
hydraulicmounts.
Note
For reasons of space, install the right trans-
mission support first. To do so, move trans-
mission to the left.
5. Removedowel pins (special tool 9595).
6. Push vacuum pipe onto switch-overvalve.
Note
The two vacuum pipes must not be confused.
Transmissioncooling will otherwise be
inadequate.

Prin1:ed in Germany -13, 1997 98637A21

"~
"1f
~
~
Tightenirlg torques:
Converterto drive
plate (M8) = 39 Nm (29 ftlb.)
Diagonalbrace to carrier side

section and body (MID) = 65 Nm (48 ftlb.
Rear cross member (V-brace)

to cross-memberpanel and
body (MID) = 65 Nm (48 ftfb.
Stabilizer to carrier side

section (M8) = 23 Nm (17 ftlb.J
Stabilizer mount to
stabilizer (MID) = 46 Nm (34 ftlb.)
Drive shaft to transmission

flange (M8) = 39 Nm (29 ftlb.)
Transmission
supportto
transmission (MID) = 65 Nm (48 ftlb.)
Hydraulic mount to carrier side

section (M8) = 23 Nm (17 ftlb.]
37 -A28 37 01 19 Removing and installing Tiptronic transmission


BO:Kster Automatic transmission -Actuation, ass. housing
37 02 35 Checking and topping up ATF fluid
Tools
235-96g
ATF filling system V.A.G1924
37 02 35 Checking and topping up ATF fluid 37 -A29

Printed in Germany -13. 1997 98637A29

Checkinlg and topping up ATF fluid
Use only ATF approved by Porsche. Air conditioningand heater must be switched
Refer to Parts Catalogue. off.
Note The vehicle must be horizontal.

The prescribed fluid level (3) is extremely
important for faultless operation of the
automatictransmission. It is correct if when
1. Suspendfilled ATF container (special tool
the ATFtemperature is between 30 °C and
40 °C there is a slight emission of ATF at V.A.G 1924) as high as possible on the ve-
the bore in the filler screw (2). hicle.
2. Place oil collection pan under the transmission.
3. ConnectPorsche System Tester 2 and call up

Lj ATFtemperature.
Note
2 At the beginning of the check, the ATF
temperature must not exceed 40 DC.
/'
4. Move selector lever to position "P"and let

engine idle.
1 2
236-96
Test conditions:
-The transmission must not be in the reduced
driving program.
The ATFtemperature must lie between

30 °C and 45 °C.
CheckingATF at an insufficient
ATF temperature causes overfilling,while
checking at an excessive ATF temperature
causesunderfilling.
Selector lever in position "P"and engine

idling.
37 -A30 37 02 35 Checking and topping up ATF fluid


5. Put on safety goggles and unscrewATF Note

filler screw (2). If ATF emergesfrom the bore
The filler hook must be carefully inserted into
of the filler screw (2) and the ATF temperatu- one of the openingsin the ATF guard cap (4),
re is 30 °C...40 DC,the ATF level is correct. which is set on the filler bore. Do not push filler
hook upwards,otherwise the oil guard cap (4)
can jump up and oft.
2
",. 0
/..
2
236-96
6. Screw in ATF filler screw with new sealing ring

and tighten to 80 Nm (59 ftlb.).
Nob~
The filler screw must be closed by the time the

ATF temperature reaches 45 °C.
7. If no ATF emerges from the filler screw (2)

although approximately 40 °C has been re-
ached, ATF must be topped up.
8. Top up ATF with special tool V.A.G 1924 until

excess ATF emerges at the bore (2).
37 102 35 Checking and topping up ATF fluid 37 -A31


BO;Kster Automatic transmission -Actuation, ass. housing
37 02 55 Changing ATF fluid
Filling capacity: approximately 9 I 6. Move selector lever to position "P"and allow

Change quantity: approximately 3.5 engine to idle.
Note 7. With enginerunning, top up ATF again until

Use only ATF approved by Porsche. excessATF emergesfrom the bore of the ATF
Refer to Parts Catalogue! filler screw (2).
1. Removetransversestrutmember. 8. With the brake pedal depressed, select all

selector lever positions, holding each position
2. Place oil collection pan under the transmission. for approximately10 s.
3. Unscrewdrain plug (1) and drain ATF. 9. Check ATF level again and top up.
Note
All instructions and test conditions for "Checking
and topping up ATFfluid" must be observed.
CJ
2
~
"" 0
1 2
236-96
No1te
The engine must not be started and the vehicle

must not be towed without ATF.
4. Replace sealing ring for ATF drain plug (1) and

tighten plug to 40 Nm (29 ftlb.).
5. UnscrewATF filler screw (2) and top up ATF

until excess ATF emerges from the bore of
the ATF filler screw.
37 02 55 Changing ATF fluid 37 -A33


37 64 19 Removing and installing inner oil tube
Tools
261-96g
Insertion aid 3381
37 154 19 Removing and installing inner oil tube 37 -A35


Notes (lin removal and installation
Notes Note
Defectivetoroidal sealing rings at inner oil tube Alwaysreplace oil tube and toroidal sealing rings.
let ATF enter the differential,which becomes
overfilled,and oil emerges from the vent of the 1. Provide oil tube with new toroidal sealing rings
differential. and give rings a thin coating of Vaseline.
In general, a removed oil tube should be 2. Insert oil tube into special tool 3381 and push
replaced. into transmissionhousingas far as the stop
on the specialtool. The open side of the
The oil tube must be inserted only with special special tool should face the outer wall of
tool 3381. Otherwisethere is a danger of the transmission.
leakage due to bending of the oil tube.
1. Removehydrauliccontrolunit.
2. Lever out oil tube with a screwdriver.
;A\::-=:~
~
\\ t
Vl'
259-96
0 Note
Do not tilt oil tube. Drive in both tube ends
equally.
258-96
37 -A3Ei 37 64 19 Removing and installing inner oil tube


It.::
Boxster Automatic transmission -A(;tuation, ass. housing
37 31 19 Removing and installing multi-function switch
Removal 4. Place transmissionjack under the

1. Hold engine by transport shackle in installed transmission.
position with special tools 10 -222A and
5. Removethe left transmissionsupport with
9591/1.
hydraulicmount.
Note
~
--7' I ~.J The fastening nut M12 (C) must not be
[ \. loosened.The transmissionsupport will
",) otherwise be damaged.
/.'/
'- ~'-~ ~
'" ~
'-
/~ 1-/
194-96 I .I.
2. Removethe left catalytic converter. AI " c

" \
3. Detach selector lever cable from deflection II J\\
lever and transmissionsupport.
435-97
A -Transmission support
B -Hydraulic mount
C -fastening nut M12
6. Releaseand disconnectcable connectionto

multi-functionswitch.
418-97
37 31 19 Removing and installing multi-function switch 37 -A37
1

~~
'-
~
7. Unscrewfastening screws and pull switch off Note

the selector shaft. Place multi-functionswitch on the selector shaft.
Do not tilt or use force: you may damage the
switch contacts.
2. Turn switch until the fitting bore (4) can be

put on the dowel pin (2) on the transmission
housing.
\!II L; ".-:cS:l./
285-96
@ ~'r
Installatil~n -=-
",,;,.-r 4
Install in the reverse order. 3 I
Put multi-functionswitch on the selector shaft.

The flat point on the serrations in the switch 286-96
(3) must lie against the flat point on the

selector shaft (1). Tightening torques
Multi-functionswitch to
transmissionhousing
(M6) = 8 Nm (6 ftlb.
Transmissionprop to
transmissionhousing
(MID) = 65 Nm (48 ftlb.)
Hydraulic mount to
carrier side section (M8) = 23 Nm (17 ftlb.)
286-96
37 -A3S: 37 31 19 Removing and installing multi-function switch


37 50 19 Removing and installing gasket for spur-gear cover
Removal
Remove silencers, 4. Unscrewflow-side coolant hose at port plate.
2. Unscrewsilencer holder from transmission,
324-96-1
324-96
3. Clampshutflow-sidecoolanthosewith special
6. Unscrewscrews of spur-gear cover,
tool 3094.
Note
- Slowlyand carefullyremove cover from

transmissionhousing. Otherwisethe spur gears
may fall out of the transmissionhousing.
\ Spur gears that have fallen onto the floor
/
~ must not be reinstalled.The gears must be
exchangedin this event.
\\1
7. Removecover and secure spur gears against
falling out.
~
0(::)0~--~ .r':"-
c \
~ \~-,
325-96
37 50 19 Removing and installing gasket for spur-gear cover 37 -A39


~~
Note 2nd step:

If the spur gears have nonethelessbeen remo- Tighten screws 1...14 in the stated sequence
ved, when they are being replaced the markings to 23 Nm (17 ftlb,),
must face outwards (awayfrom transmission),
Installin~:
1. Ensurefaultless seating of the dowel sleeve,
2. Screw two centring pins (special tool 9321)

into the transmission housing, put new gasket
on and fit cover.
3. Tighten screws in two steps.
1st step:
Tighten screws 1, 2 and 3 by hand. Ensure
that the gap between cover and transmission
housing is equallyreduced all round.
323-96
A -Dowel sleeve
4. Check and top up ATF level (see Page

37 -A29).
37 -A40 37 50 19 Removing and installing gasket for spur-gear cover


BO:Kster Automatic transmission -Ac:tuation, ass. housing
37 33 19 Removing and installing sealing ring for selector shaft
Tools
330-96g
Mandrel 3385
37 33 19 Removing and installing sealing ring for selector shaft 37 -A41

Prirlted in Germany. 13, 1997 98637A29

Removilrlg and installing sealing ring for selector shaft
Removal
1. Removemulti-function
switch(seePage 4. Pierce sealing ring with small screwdriver and
37 -A37). pullout.
2. Detach push rod at selector lever,
3. Drive out roll pin (1) until the selector lever

can be pulled off from the shaft.
302-96
Installation
1. Thinlycoat sealing lip and circumference of
sealing ring with Vaseline.
301-96
2. Drive in sealing ring with special tool 3385 as

far as the mountingface.
37 -A42 37 33 19 Removing and installing sealing ring for selector shaft


Bo~~ster Automatic transmission -Actuation, ass. housing
Note
The open side faces the transmission.
Y)
\!Ii ~ ~
303-96
37 33 19 Removing and installing sealing ring for selector shaft 37 -A43

Primed in Germany -13, 1997 98637A29

~
Boxster Automatic transmission -Gears, control
38, 77 19 Removing and installing hydraulic control unit
'-"
0 ~
A
~
'\
.-;-" ,
0
38 77 19 Removing and installing hydraulic control unit 38 -Al

Printed in Germany, 1996 98638Al


Bo)[ster Automatic transmission -Gears, control
Note:
No.. Designation Qty. Removal Installation
1 ATF drain plug 1 Tighteningtorque 40 Nm

(29 ftlb.)
2 Sealingring 1 Alwaysreplace
3 ATF filler screw (hexagon 1 Tighteningtorque 80 Nm

socket 17 mm) (59 ftlb.)
4 Toroidalsealingring 1 Always replace
5 Screw 27 Loosencrosswise Tighten crosswise in sev-

eral stages. Tightening
torque 10 Nm (7 ftlb.)
6 ATF pan
7 Gasket 1 Alwaysreplace
8 Magnet 4 Cleanand lay in the
beads of the ATF pan. En-
sure contact over full area
9 Screw 2 Tighteningtorque 6 Nm
(4 ftlb.)
10 ATF filter 1 Thinlycoat gasket at suc-
tion collar with Vaseline
11 Securingclasp 1 Holdingtongue must en-

gage
12 Screw 16 1 screw M6 x 30 and See Removingand instal-
15 screws M6 x 60 ling hydrauliccontrol unit.
Tighteningtorque
8 Nm (6 ftlb.)
13 Screw M6 x 60 1
14 Holderfor wiringharness
15 Hydrauliccontrolunit 1 See Page 38 -A7
16 Wiringharness 1 See Page 38 -A15
17 Toroidalsealingring 2 Alwaysreplaceand coat

withVaseline
18 Screw 1 Tightening torque 6 Nm
(4 ftlb.)
38 77 19 Removing and installing hydraulic control unit 38-A3


Automatic transmission -Gears, control Boxster
Note:
No. D,esignation Qty. Removal Installation
19 Sensor for transmission 1 See Page 38 -All

input speed
20 Spacer sleeve 1
(height20 mm)
(4 ftlb.)
22 Holder 1
23 Pressure regulator 1 (with 1 Removehydrauliccontrol Thinly coat toroidal seal.

toroidal sealing ring) unit. ing ring with Vaseline
24 Screw 4
25 Holder 2
26 Solenoidvalve 1 (without 1 Unscrewguideplatefor Do not tighten screws for

toroidal sealing ring) parking-lock
mechanism guide plate in selector
lever position "po.Tighte-
ning torque 23 Nm
(17 ftlb.)
27 Pressure regulator 2 (with 1 Thinly coat toroidal seal-
toroidal sealing ring) ing ring with Vaseline


30 Solenoidvalve 2 (without 1
toroidal sealing ring)
31 Solenoidvalve 3 (without 1
toroidal sealing ring)
32 Screw 1 Tighteningtorque6 Nm
(4 ftlb.)
33 Sensorfor transmission 1 See Page 38 -A13
speed
34 Spacersleeve(height 1
8 mm)
35 Oiltube 1 See Page 37 -Al7 Alwaysreplace
36 Toroidalsealingring 2 Alwaysreplaceand thinly
coatwithVaseline
38 -A4 38 77 19 Removing and installing hydraulic control unit


Boxster Automatic transmission ..Gears, control
Note:
No" Designation Qty. Removal Installation
(6 ftlb.)
38 Multi-function
switch 1 See Page 37 -A19
. 38 77 19 Removing and installing hydraulic control unit

38 .AS
BO:Kster Automatic transmission -Gears, control
Notes on removal and installation
Note 5. Pulloff securingclaspfor wiringharnessplug.

Do not let engine run with the ATF pan removed
or without ATFfilling.
Removal "47
1. Removetransversememberpanel.
~
2. UnscrewATFdrainscrewanddrainATFfluid. I~
3. RemoveATF pan (loosen screws crosswise)
4. RemoveATFfilter.
.../ "'"
242 -96
6. Pulloff plugsfor transmissionspeedsensors,

C==>l \
c-J I -'--'
c==>
c==> '\
-,/1
I
~ J---t;
/'
241 -96 " /\
" '-'"
.-.,
J!/
I~'
243 -96
7. Unscrewfastening screws for hydrauliccon-

trol unit.
38 77 19 Removing and installing hydraulic control unit 38 -A7

~~,--1
.'/~
~
Note 2. Carefullyput on hydrauliccontrol unit and in-

Onlythe marked screws may be unscrewed, sert the pin of the detent disc (1) into the
groove of the selector valve (2).
282-96
3. Firsttightenscrewsfor hydrauliccontrolunit
244 -96
(arrows)handtight. Thentightento 8 Nm
(6 ftlb.)from insideoutwards.
8. Take hydrauliccontrol unit off transmission
and follow up wiring harnessplug.
~'ote
Do not lay removed hydrauliccontrol unit on the
sensor for transmissioninput speed at the
reverse side of the hydrauliccontrol unit. This
could damage the sensor.
Installation
Instail in reverse order, observingthe following
points:
1. Thinly coat toroidal sealing rings for wiring har-

ness plugs with Vaselineand insert plug into
transmissionhousing.
244 -96
38 -A8 38 77 19 Removing and installing hydraulic control unit

98638Al Printed in Germany. 1996

Box:ster Automatic transmission -Gears, control
4. Push on securing clasp for wiring harness Tightening torques:

plug and let holding tongue engage.
Drain plug to
ATF pan 40 Nm (29 ftlb,
"===1
ATF pan to
transmissionhousing 10 Nm (7 ftlb.:
I~ ATF sieve to
hydrauliccontrolunit 6 Nm (4 ftlb.)
"" Hydrauliccontrol unit to

transmissionhousing 8 Nm (6 ftlb.)
242 -96
5. Thinly coat gasket on the suction collar of the

ATF strainer with Vaselineand install strainer.
6. Replacegasket for ATF pan.
7. Cleanall four magnets in the beads of the ATF

pan and ensure there is contact over the full
area of the ATF pan.
8. Tightenscrewsof the ATFpancrosswisein

severalstages.
9. Top up ATFfluid
~ (see Page 37 -All).
8
38 77 19 Removing and installing hydraulic control unit 38 -A9

'
Bo):ster Automatic transmission -Gears, control
38 17 19 Removing and installing sensor for transmission input speed
Note
Do not reuse speed sensors that have fallen
down (permanentmagnet breaks),
Removal
2. Removesensor,
1 = Sensor 255 -96
2 = Spacer sleeves (height 20 mm)
Installation
1. Using the two spacer sleeves,install sensor
and tighten fastening screws to 6 Nm (4 ftlb.).
38 17 19 Removing and installing sensor for transmission input speed 38 -All

Prir1itedin Germany, 1996 98638Al
BoJ(ster Automatic transmission -Gears, control
38 17 19 Removing and installing sensor for transmission speed
Note
Do not reuse speed sensors that have fallen

down (permanentmagnet breaks),
Removal
1. RemoveATFpan.
2. Removesensor.
1 = Spacer sleeve (height 8 mm) 256 -96

2 = Sensor
Inst:allation
1. Usingthe spacersleeve,installsensorand
tightenfasteningscrewto 6 Nm (4 ftlb.J.
38 17 19 Removing and installing sensor for transmission speed 38 -A13

Primed in Germany, 1996 98638Al

Boxster Automatic transmission ..Gears, control
38 18 19 Removing and installing wiring har,ness
Not.!
The ATFtemperature sensor is integrated in the
transmissionwiring harness. If damaged,the
complete transmissionwiring harness must be
replaced.
Removal
2. Disconnectplugconnectionsfrom the sole-

noidvalvesandfrom sensorfor transmission
inputspeed.
3. Detachwiringharnessfrom the retainers.
Installation
Installin reverseorder.
1. Insertwiring harness plug with the flat point

(arrow)to the ATF pan.
260 -96
38 :L8 19 Removing and installing wiring harness 38 -A15

Print,ed in Germany, 1996 98638Al

BO;Kster Automatic transmission -Gears, control
38 60 19 Removing and installing ATF cooler
Tools
38600001

Hose clamp 3094
38 60 19 Removing and installing ATF cooler 38 -AI7

Primed in Germany -30, 1999 98638Al

Removill1gand installing ATF cooler

"
-, I~\"\"\
Removal / ~--- \
1. Removerear underside panel (only for

transmission type A86jO5). -
2. Clamp shut coolant hoses (flow and return
sides) with special tool 3094. -
G:f:)O .L
~ = --~ /\/
\. ~
TransmissionA86/00 325_96
3. Removecatalytic converter on the right.
5. Unscrewthe fastening screws for the ATF

cooler with a 1orx 130 (3/8 inch) screwdriver
insert.
TransmissionA86jOO 319_96
356_96
38 -A18 38 60 19 Removing and installing ATF cooler


~
~
Boxster Automatic transmission ,. Gears, control
Note
If necessary,use a mirror when unscrewingthe
top two screws.
Installation
1. Replacetoroidal sealing rings and coat with
ATF.
2. Check and top up ATF

(refer to Servo No. 37 02 35).
3. Top up engine coolant level and bleed system

(refer to Servo No. 19 38 17).
Tightening torques
ATFcoolerto port plate (M6) = 10 Nm(7.5ftlb.)
. 3860
Printed
19 Removing
in Germany -30,
and installing
1999
ATF cooler
98638A1

38 -A19
Boxster Final drive -Differential, differential lock
391 90 55 Changing and checking transmission oil in final drive
Filling capacity: approximately0,8 I
Use only transmission oil approved by

Porsche.
Refer to Parts Catalogue!
Note
There is no oil drain plug on the final drive.
For oil changes,the cover of the final drive must
be removed (see Page 39 -A7).
1. Unscrew screw plug (arrow)and drain oil with

the vehicle parked on a horizontalsurface.
234-96
2. Fill in 0.8 litres of transmission oil with special

tool (VAG 1924).
Note
As there is a baffle plate in the cover for the
final drive, fill in the oil very slowly.
3. Replace toroidal sealing ring for plug and

tighten to 30 Nm (22 ftlb.).
39 90 55 Changing and checking transmission oil in final drive 39 -Al


39 01 37 Disassembling and assembling final drive
39 01 37 Disassembling and assembling final drive 39 -A3

Primted in Germany, 1996 98639Al

Final drive -Differential, diffe!rential lock Boxster
r'liote
The parts shown in the figure can also be removedwith the transmissioninstalled.
Note:
No. D'esignation Qty. Removal Installation
Screw 1 Tighteningtorque 25 Nm
(18 ftlb.)
2 Short flanged shaft 1
(17 ftlb.)
4 Cover for final drive 1
5 Taperedrollerbearing 1 Withoutpress fit

outer race
6 Adjusting shim x Is calibrated and must not
be exchangedfor an ap-
proximate substitute
Sealingring 1 SeePage39-A13
8 Plug 1 Tighteningtorque 30 Nm
(22 ftlb.)
9 Toroidal sealing ring 1 Always replace. Coat with

transmissionoil
10 Toroidalsealingring 1 See Page 39 -Ala Alwaysreplace
11 Differential 1
12 Tapered roller bearing 1 Without press fit
outer race
13 Adjustingshim x Is calibrated and must not
be exchangedfor an ap-
proximate substitute
14 Screw 3 Tighteningtorque23 Nm
(17 ftlb.)
15 Longflangedshaft 1 See Page 39 -All
16 Toroidal sealing ring 1 Alwaysreplace.Coatwith

(square) transmission
oil
17 Snap ring 1
18 Ballbearing 1
39 -A4 39 01 37 Dis,assembling and assembling final drive


Note:
No. Designation Qty. Removal Installation
19 Mountingsaddle
20 Sealingring 1 See Page 39 -A19 Always replace
21 Doublesealingring 1 See Page. 39 -A23 Always replace
22 Rollpin 1
23 Selector lever 1
24 Sealingring 1 See Page 37 -A23 Alwaysreplace
(17 ftlb.)
26 Housingcover 1
27 Gasket 1 See Page 37 -A21 Alwaysreplace
28 Dowelsleeve 2
39 IDI 37 Disassembling and assembling final drive 39 -AS


39 09 19 Removing and installing differenti~11
Tools
321 .96

1 Supporting bridge 10-222A
2 Support feet 9591/1
3 Hose clamp 3094
3909 19 Removing and installing differential 39 -A7


Final drive -Differential, differential lock Boxster
Removing and installing differential
Removal
1. Hold engine by transport shackle in installed

position with special tools 10-222Aand
9591/1.
313 -96
7. Place oil pan under the transmission.
8. Unscrewfastening screw for flanged shaft, se-

194-96 cure flanged shaft with mandrel againstturn-
ing.
2. Remove right rear wheel.
3. Removediagonalbracesundcross-member L
panel.
4. Removeright catalytic converter.
5. Uncoupledrive shafton the transmission

side
and protectshaftfrom damage(usepieceof
hosewith diameterof approximately30 mm).
6. Detach stabilizer/stabilizer mount ball joint (A),

toe control arm (8) and control arm (C)from
wheel carrier (see Group 42, Disassembling
and assemblingwheel suspension). 314- 96
9. Unscrewtransmissionsupportwith hydraulic
mountat transmission
and at carrierside mem-
ber.
39 -AS 39 09 19 Removing and installing differential

98639Al Printed in Germany, 1996

Note
Fastening nut "C" (M12) must not be loosened. 11. Unscrewcoolant return-sidehose at ATF
Otherwisethe transmission prop will be dama- cooler and at cover for final drive.
ged.
318.96
435-97
A -Transmission support 12. Unscrewcover screws,reversingthe
B -Hydraulic mount
C -fastening nut M12 indicatedorderfor tightening12...1,
andremovecover.
10. Clamp shut coolant return-sidehose with
special tool 3094.
320-96
319-96
391 09 19 Removing and installing differential 39 -A9


Final drive -Differential, diff.~rential lock Boxster
13. Take differential,bearing outer race (1) and

adjusting shim (2) out of the transmission
housing by hand.
Note
The adjusting shim (2) is calibrated and must
not be exchangedfor an approximate substitute,
320-96
3. Add transmissionoil for final drive

(see Page 39 -AI).
Tightening torques:
306-96
Cover for final drive
to transmission (M8) = 23 Nm (17 ftlb.)
Installation
Coolantline to cover
1. Replace toroidal sealing ring for final drive
for final drive and port
cover and coat with transmission oil. = 23 Nm (17 ftlb.:
plate (M8)
2. Tighten screws for cover in two steps, Short flanged shaft to

transmission (M8) = 25 Nm {I8 ftlb.
1ststep:
Tighten screws 1, 2 and 3 by hand, Diagonalbrace to carrier
side member (MIO) = 65 Nm (48 ftlb.)
2nd step:
Tighten screws 1...12 in the stated Stabilizer mountto stabili-
order to 23 Nm (17 ftlb.). zer (MID) = 46 Nm (34 ftlb.)
Drive shaft to transmission

flange (M8) = 39 Nm (29 ftlb.)
Transmission support to
transmission (M1 0) = 65 Nm (48 ftlb.:
39 -AIO 39 09 19 Removing and installing differential


Boxster Final drive -Differential, Idifferential lock
Hydraulic mount to carrier

side member (M8) = 23 Nm(17 ftlb.J
Control arm to wheel

carrier (M12) = 75 Nm (55 ftlb.)
Toe control arm to wheel

carrier (M12) = 75 Nm (55 ftlb.)
39 09 19 Removing and installing differential 39 -All

BO:Kster Final drive -Differential, differential lock
39 22 19 Removing and installing sealing ring for short flanged shaft
Tools
312.96

1 Hook VW681
2 Pressurepiece 3382
39 22 19 Removing and installing sealing ring for short flanged shaft 39 -A13
Prinrted in Germany, 1996 98639Al
Final drive -Differential, diffeirential lock Boxster
Removing and installing sealing ring for short flanged shaft
Removal
1. Removerightrear wheel.
2. Uncoupledrive shafton the righton the trans-

missionside and protectshaftfrom damage
(usepieceof hosewithdiameterof approxi-
mately30 mm).
3. Detach stabilizer/stabilizer mount ball joint (A),

toe control arm (8) and control arm (C)from
whee! carrier (see Group42, Disassembling
and assemblingwheel suspension).
314-96
\.
9. Pull out flanged shaft.
~ 10. Removesealingring with specialtool

VW681.
I'c..tlC
C=---,
r, "
, '~ C '
I~~~
313 -96
5. Unscrewfastening screw for flanged shaft, se-

cure flanged shaft with mandrel againstturn-
ing.
315 -96
39 -Al.J 39 22 19 Removing and installing sealing ring for short flanged shaft

~
Box~ster Final drive -Differential, differential lock
Installation
1. Thinly coat sealing lip and circumference of
sealing ring with Vaselineand insert sealing
ring with special tool 3382 up to the stop.
316 -96
Note
Thesealingring mustfit in the housingat the
samedepthall round.
2. Check transmissionoil in final drive and top

up if necessary.

39 25 19 Removing and installing long flanged shaft
Removal Installing
1. Removeleft rearwheel. 1. Replacesquaresealingring in mounting
saddle.
2. Drainrear-axleoil (seePage39. AI).
2. Check flanged shaft for burrs and sharp
Note edges on the transmissionend of the shaft
Drainingthe oil preventsrear-axleoil entering (arrow)and deburr if necessary.
the ATF.
This would cause malfunctionsof the hydraulic
transmissioncontrol system.
5. Uncoupleleft drive shaft on the transmission

side and protect shaft from damage (use
f
piece of hose with diameter of approximately
30 mm).
\ (
4. Unscrewfastening screw (A)for coolant pipe
and (8) for the mounting saddle.
J
\:r \ ,(\ -..i 300 -96
/
---
3. Carefullyinsertflangedshaftinto the trans-
mission.
( ,
'-
~::::f=~
0; ) )Q~ ~ - Note
Whilebeing inserted,the flanged shaft must be
°_-/ ),.- ~
I\B ./
carefullyguided with the hand in order to pre-
vent damageto the double sealing ring in the
---:/
~ transmission.
298 -96 4. Refillrear-axle

oil.
5. Carefullypull out flangedshaft.
39 25 19 Removing and installing long flanged shaft 39 -A17

Primed in Germany, 1996 98639A1
/~ Purchased from www.WorkshopManuals.co.uk

Tightening torques:
Mountingsaddlefor flanged
shaftto transmission = 23 Nm(17 ftlb.:
Coolantpipe to
mounting saddle = 23 Nm (17 ftlb.
Driveshaftto
flangedshaft = 39 Nm (29 ftlb.:
39 -Ala 39 25 19 Removing and installing long flanged shaft


B~lxster Final drive -Differential, differential lock
3~t 22 19 Removingand installing sealing ring for long flanged shaft
Tools
"""""VVY" v
",v",~VYY"~V
v",,""YV~~~y"y~y B
Nol, Designation Special tool Explanation

A Pressurepiece 9615
13 Inserterandpuller P254
39 22 19 Removing and installing sealing ring for long flanged shaft 39 -A19
Prillted in Germany -5, 1996 98639A1

Final drive -Differential, differential lock Boxster
Removil1lgand installing sealing ring for long flanged shaft
Rf~moval
1. Removelongflangedshaft(see 4. Leversealingring out of mountingsaddlewith

Page39 -All). largescrewdriver.
2. Removesnapringfor ball bearing. Installing

1. Push new sealing ring up to the stop with spe-
cial tool 9615.
P254
@
~ ~
;.'1,.'~;--;~::~
9615
331 -96
3. Pressflangedshaftout of mountingsaddle. 333 -96
332 -96
39 -A20 39 22 19 Removing and installing sealing ring for long flanged shaft

~
Box~;ter Final drive -Differential, differential lock
2. Pressmountingsaddlewith ballbearingonto
flangedshaft.
18
334 -9f.
3. Insertsnapring.
4. Installflangedshaft;checkandtop up trans-
missibnoil in finaldrive.
39 25 37 Removing and installing sealing ring for long flanged shaft 39 -A21
Bo)(ster Final drive -Differential, differential lock
39 15 19 Removing and installing final driveltransmission housing double sealing

ring
Tools
No.. Designation Special tool Explanation

1 Hook Wv'681
2 Pressurepiece 3383
39 15 19 Removing and installing final drive/transmission housing double sealing ring 39 -A23
Printed in Germany. 1996 98639Al

Removing and installing final drive/transmission housing double sealing ring
Note Note
A defective double sealing ring allows ATF or Theadjustingshimis calibratedand cannotbe
transmissionoil to escape via the middle vent exchangedfor an approximatesubstitute.
opening of the shaft seal (betweenthe two seal-
ing lips) intolthe converter bell housing.
A defective ~ouble sealing ring can also let ATF
enter the differential. The latter is overfilled,and
oil emerges latthe differential vent opening.
Removal
1. Unboltrear wheels.
2. Removedifferential
(see Page 39 -A7).
3. Removelongflangedshaft 306 -96
(seePage39 -All).
5. Carefullypull out gasketwith specialtool
4. Take bearing outer race (1) and adjusting VW681.
shim (2) out of the transmissionhousing by
hand.
39 -A24 39 15 19 Removing and installing final drive/transmission housing double sealing ring
I 98639A1 Printed in Germany, 1996

Bo):ster Final drive -Differential, differential lock
Note 3. Pushsealingring up on the specialtool so

Special tool VW681 must be applied behindthe thatthe projectingsealinglip (arrow)facesthe
two se~ling lips of the sealingring. Do not apply specialtool.
to the tircumference of the sealingring, since
otherwise the contact area in the transmission
housingwill be damaged. Whilelevering it out,
guide I~ver carefully.
308-96
4. Drive sealing ring in to the stop with special

tool 3383.
307-96
Installation
1. Cheqkseat of sealingring in transmission
housingfor damage.
2. Thinlycoatcircumference andsealinglip of
seali~gring withVaseline.
309 -96
39 15 19 Removing and installing final drive/transmission housing double sealing ring 39 -A25

986 Group 3 Transmission-Automatic PDF

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www.WorkshopManuals.co.

WKD 483 521

Purchased from www.WorkshopManuals.co.uk

The integration of the technical informationpublishedin the "Boxster"TechnicalManualwith the

The "Boxster"TechnicalManualconsists of 15 folders, subdividedinto the following Groups

Purchased from www.WorkshopManuals.co.uk

The"Boxster"TechnicalManualhasthe samestructurein eachfolder,with the followingbreakdownfor

Title page, "Boxster" Technical Manual

Title page: "Technical Information"

Title page: "Repair"

Followingthe Technical Information,separated by a title page, the instructions on repairs -assigned

Theinstructionson repairswill be extendedand updatedby meansof supplements.

Sheetsthat alreadyexistin the "Boxster"TechnicalManualandare updatedor revisedand thereby

Purchased from www.WorkshopManuals.co.uk

Group 0: Entire vehicle -General 0

Purchased from www.WorkshopManuals.co.uk

Group 4: Running gear 4

Group 8: Air conditioning 8

Group 9: Circuit diagrams 9

Overview of repair groups

Purchased from www.WorkshopManuals.co.uk

3 Transmission -Automatic transmission

32 Automatic clutch -Torque converter

37 Automatic transmission -Actuation, ass. housing

38 Automatic transmission -Gears, contrcll

3 Transmission -Automatic transmission

Purchased from www.WorkshopManuals.co.uk

39 Final drive -Differential, differential lock

39 9055 Changingand checking transmissionoil in final drive. 39 -A I

2 3 Transmission -Automatic transmission

Purchased from www.WorkshopManuals.co.uk

3 Technical data (Tiptronic transmission A86)

5-speed Tiptronic transmission AS6

Type Code letter Equipment Installed in Model year

A86/00 5-speed Boxster 97/98/99

3 Technical data (Tiptronic transmission A86) 3-Al

Purchased from www.WorkshopManuals.co.uk

Identification of Tiptronic transmission

3 -A2 3 Technical data (Tiptronic transmission AS6)

Purchased from www.WorkshopManuals.co.uk

3 Technical data (Tiptronic transmission A86) 3 -A3

Purchased from www.WorkshopManuals.co.uk

1- Torqueconverter 6 -ATF drain plug

3 T4~chnical data (Tiptronic transmission A86) 3 -AS

Purchased from www.WorkshopManuals.co.uk

Tightening torques for Tiptronic transmission

Location Thread Tightening torque

ATF filler screw

ATF drain plug

ATF strainer to hydraulic control unit M5 6 (4)

Sensor for transmission input

Sensor for transmission speed to

Cover for final drive to

Mountingsaddle for long flanged

Housingfor spur gear to

3 Technical data (Tiptronic transmission AS6) 3 -A7

Purchased from www.WorkshopManuals.co.uk

32 50 19 Removing and installing torque colnverter

Item Designation Special tool Explanation

32 !50 19 Removing and installing torque converter 32 -Al

Purchased from www.WorkshopManuals.co.uk

Notes on removal and installation

Removal 2. Fixthe converterin installationpositionwith