Man Trans
Technical Information and Restoration Parts for the 928

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Manual Transmission (MAX 150 Points)

The 928 used two different transmissions with a number of options.  From 1978 to 1984 Porsche provided the manual transmission.  It was know to have syncro problems and a long shift throw.  In 1985 with the 32 valve engine the 928 was modified with Borg Warner syncros that were more reliable and shifted smoother.

The clutch prior to 1986 was a dual disk clutch.  While very strong and reliable it is more difficult to adjust.  Both systems have there advantages and disadvantages.

bulletHydraulic System - The clutch is operated by a hydraulic master / slave system.  The clutch master is mounted under the brake booster on the left fender well.  It is fed off a blue flex hose from the brake master reservoir.  As the blue hose ages it expands and becomes soft.  When the hose fails all of the brake fluid is drained from the reservoir.  The clutch master also fails over time. One of the things to check when the car is cold is the level of the clutch pedal.  If it is low or sticks then the master is bad.  Often when the car is warm the clutch will operate normally.  There is a flex hose that runs from the master to the slave cylinder mounted under the car n the bell housing.  This house can break causing the clutch system to fail. All of these areas should be checked for leaks. 
(Deduct 15 points if the clutch hydraulic system is leaking, operating improperly and has not been replaced in the past 10 years)
bulletClutch - Checking the clutch is about the same on all cars.  It should not chatter when taking off in first.  The clutch should not slip when accelerating in a higher gears.  the engine in the 928 is strong enough to put a lot of stress on the clutch.  If when running in 4th or 5th gear at 2000 RPM, the clutch starts to slip as the car accelerates then it is bad.  Test the clutch for drag by finding a level spot stopping the car, putting it in first gear and holding the clutch pedal to the floor.  If the car starts to creep then the clutch is dragging.  
(Deduct 30 points for any problems with the clutch or if it has not been changed in the past 50K miles)
bulletTransmission - The transmission should shift smoothly both up and down.  On the older pre 1985 cars it is normal to feel a little hesitation on the first to second shift.  It is also normal for the shift into first to be a little stiff from time to time.  Unfortunately there are no small transmission problems other than minor leaks.  
(Deduct 75 points for noises and bad syncros.  Deduct 10 points for minor leaks)
bulletTorque Tube - Put the car in neutral and depress the clutch and slowly let it out.  There should be very little difference in the noise level.  If there a significant increase in noise, the bearings in the torque tube are worn and need replacing. 
(Deduct 30 points for a noisy torque tube)
bulletLimited Slip Differential -  Some cars came with limited slip differentials.   Limited slip improves handling and is a desired feature.  Jack up the rear of the car and spin the rear tire.  If they spin in different directions then the there is no limited slip option installed.  Do not rely on the option codes.  When spinning the wheels listen for clunking or bearing noises. 
(Deduct 30 points for a noisy differential.  Add 20 points for a properly functioning limited slip)
 

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