Removing and Installing Transmission
Removing and installing transmission
Preliminary work
Preliminary work for removing transmission
1. Remove covers in engine compartment to the right and rear, please refer to Vehicle/ Body and Frame/ Acess Cover, Engine/ Service and Repair
2. Remove Y-shaped pipe, please refer to: Vehicle/ Powertrain Management/ Fuel Delivery and Air Induction/ Intake Air Duct/ Service and Repair and Vehicle/ Powertrain Management/ Fuel Delivery and Air Induction/ Intake Air Plenum/
3. Remove engine guard, please refer to: Vehicle/ Body and Frame/ Exterior Moulding/Trim/ Underbody Cover/ Service and Repair
4. Remove exhaust system, please refer to: Vehicle/ Engine, Cooling and Exhaust/ Exhaust System/ Service and Repair
5. Remove rear cardan shaft, please refer to: Vehicle/ Transmission and Drivetrain/ Drive/Propeller Shafts, Bearing and Joints/ Drive Propeller Shaft/ Service and Repair
6. Remove front cardan shaft, please refer to: Vehicle/ Transmission and Drivetrain/ Drive/Propeller Shafts, Bearing and Joints/ Drive Propeller Shaft/ Service and Repair
7. Remove catalytic converter on left side, please refer to: Vehicle/ Powertrain Management/ Emissions Control Systems/ Catalytic Converter/ Service and Repair
Removing transmission
Information:
^ The line connections on the transmission and the ends of the ATF lines must be closed off after the lines have been separated from the transmission!
1. Moving selector lever to position N
2. Remove torque converter support on engine side.
Torque converter support screw
Torque converter support
3. Remove heat shield on the left of the transmission. To do this, unscrew three fastening screws -arrow-.
Left heat shield
4. Remove heat shield on the right of the transmission. To do this, unscrew three fastening screws -arrow-.
Right heat shield
5. Remove transfer gear.
6. Support engine-transmission unit on converter bell housing with a (material) -00000- on the suspension subframe.
Supporting engine/transmission unit
7. Remove heat shield on the steering gear.
Heat shield on steering gear
8. Pull off plug connections on Tiptronic transmission -1,2,3-.
Tiptronic plug connections
9. Remove reference mark sender on the converter bell housing -arrow-.
Reference mark sender
10. Unscrew coolant pipe holder screws -arrows- on the converter bell housing.
Coolant pipes on converter bell housing
11. Remove retaining clip -A- on the holder.
Selector lever cable connection
12. Unscrew selector lever cable from the ball joint with universal disassembly tool -NR.21-.
Removing selector cable
13. Remove stopper -1- used to seal the converter assembly opening.
Removing stopper from assembly opening
Information:
^ A second fitter is required to unscrew or screw in the converter screws.
^ The converter screws must be replaced.
14. Remove converter screws. Observe the following steps for this purpose.
Removing converter screws
15. Turn crankshaft clockwise using special tool socket-wrench insert -97140-.
16. Insert special tool locating pin -95950- into the front bore on the converter bell housing -arrow- and hold upwards with slight pressure until it engages when the crankshaft is turned.
17. Position special tool bit insert -96880- on converter screw through opening in the engine block, connect bit snap-on head and special insert -96870- one after the other.
Opening for converter screws
18. Remove special tool locating pin -95950- before loosening the converter screws.
19. Unscrew converter screw and twist out.
20. Complete the steps described above for the other five screws.
Warning:
Hot fluid
^ Danger of scalding
-> Let the fluid cool down.
-> Wear personal protective gear.
Warning:
Hot fluid
^ Danger of scalding
-> Let the fluid cool down.
-> Wear personal protective gear.
21. Loosen ATF lines and lock connections.
ATF line on transmission
22. Lift transmission using transmission jack and mounting plate on the ATF pan and secure with belts.
23. Remove -Material 00000- base.
Supporting engine/transmission unit
24. Unscrew engine/transmission flange screws -arrow- and two screws on the underside.
Fastening screws securing transmission to engine
Tool recommendation
25. Disengage vent line at the upper side of the transfer gear while lowering it.
26. Gradually extend transmission.
Installing transmission
Information:
^ A second fitter is required to unscrew or screw in the converter screws.
^ The converter screws must be replaced.
Information:
^ The adaptation values must be reset using the Porsche System Tester when the transmission is renewed/replaced.
Information:
^ Because of the limited space between the engine and the radiator, the fixing pin can only be inserted at one point.
^ Insert special tool in front of the fixing point in the belt pulley and then turn towards the fixing point. To remove, turn engine back slightly and remove fixing pin.
1. Fix crankshaft using special tool locating pin -95951-.
Fixing the crankshaft
2. Insert special tool centering pin -96890- into the torque converter.
Converter centering pin
3. Gradually run in transmission. Thread centering pin through and replace vent line.
4. Screw in engine/transmission flange screws -arrow- and two screws on the underside. -> Tightening torque: 80 Nm (59 ftlb.)
Fastening screws securing transmission to engine
Tool recommendation
5. Remove special tool centering pin -96890- through the opening in the engine block.
6. Support transmission with a (material) -00000- between converter bell housing and suspension subframe.
Supporting the engine/transmission unit
Caution:
Damage to converter screws due to excessive tightening torque.
-> Observe adjusting value for torque wrench. 65 Nm (48 ftlb.) on torque wrench = 85 Nm (63 ftlb.) on the screw.
7. Screw in new converter screws:
8. Place screw on special tool bit insert -96880- and screw in the first screw.
Opening for converter screws
9. Position bit snap-on head and special tool insert part -96870- and screw in screw. -> Tightening torque: 85 Nm (63 ftlb.)
10. Remove special tool locating pin -95951- on the crankshaft.
11. Turn crankshaft clockwise using special tool socket-wrench insert -97140-.
12. Insert special tool locating pin -95950- into the opening on the converter bell housing -arrow- and hold with light pressure until it engages when the crankshaft is turned.
Disconnecting converter screws
13. Pull out special tool locating pin -95950- before tightening to the specified tightening torque.
14. Complete the steps described above for the other screws.
15. Insert stopper -1- for converter assembly opening. To do this, moisten the groove on the stopper with water.
Stopper used to seal converter opening
16. Starting at the cut-out in the engine block -1-, press in the stopper all the way round from position -2-3-.
Stopper
17. Check the position of the stopper -2- using an inspection mirror -1-. When doing this, make sure that the sealing lip -3- makes contact all the way round.
Installation position of stopper
Warning:
Hot fluid
^ Danger of scalding
-> Let the fluid cool down.
-> Wear personal protective gear.
Warning:
Hot fluid
^ Danger of scalding
-> Let the fluid cool down.
-> Wear personal protective gear.
18. Position ATF lines on transmission and screw on tightly. -> Tightening torque: 25 Nm (19 ftlb.)
ATF line to transmission
19. Engage selector lever cable on holder and insert safety clip -A-.
Selector lever cable connection
20. Press selector lever cable onto the ball head -arrow-.
21. Screw in fastening screws for coolant pipe holder -arrow- at the converter bell housing. -> Tightening torque: 9 Nm (6.5 ftlb.)
Coolant pipes to converter bell housing
22. Install reference mark sender on the converter bell housing -arrow-. -> Tightening torque: 10 Nm (7.5 ftlb.)
Reference mark sender to converter bell housing
23. Install catalytic converters on left side.
24. Move oxygen sensor cable behind catalytic converter upwards.
25. Install heat shield on the steering gear. -> Tightening torque: 10 Nm (7.5 ftlb.)
Heat shield to steering gear
26. Fit plug connections on Tiptronic transmission -1,2,3-.
Tiptronic plug connections
27. Install transfer gear.
28. Install heat shield on the right of the transmission. To do this, screw in three fastening screws -arrow-. -> Tightening torque: 10 Nm (7.5 ftlb.)
Right heat shield
29. Install heat shield on the left of the transmission. To do this, screw in three fastening screws -arrow-. -> Tightening torque: 10 Nm (7.5 ftlb.)
Left heat shield
30. Connect oxygen sensor cable to the plenum panel.
Cable for oxygen sensors
31. Flange torque converter support on engine side. -> Tightening torque: 60 Nm (44 ftlb.)
Torque converter support screw
Warning:
Hot fluid
^ Danger of scalding
-> Let the fluid cool down.
-> Wear personal protective gear.
Warning:
Hot fluid
^ Danger of scalding
-> Let the fluid cool down.
-> Wear personal protective gear.
32. Unscrew ATF inspection plug -A- and fill in ATF until a constant discharge is visible at the lifting tube.
ATF pan control screw/filler screw
33. Screw in ATF inspection plug -A-. -> Tightening torque: 70 Nm (52 ftlb.)
Subsequent work
Subsequent work for installing transmission
1. Fit engine guard, please refer to: Vehicle/ Body and Frame/ Exterior Moulding/Trim/ Underbody Cover/ Service and Repair
2. Install front cardan shaft, please refer to: Vehicle/ Transmission and Drivetrain/ Drive/Propeller Shafts, Bearings and Joints/ Drive/Propeller Shaft/ Service and Repair
3. Install rear cardan shaft, please refer to: Vehicle/ Transmission and Drivetrain/ Drive/Propeller Shafts, Bearings and Joints/ Drive/Propeller Shaft/ Service and Repair
4. Install the exhaust system, please refer to: Vehicle/ Engine, Cooling and Exhaust/ Exhaust System/ Service and Repair
5. Install engine compartment cover at the right and rear, please refer to: Vehicle/ Body and Frame/ Access Cover, Engine/ Service and Repair
6. Check and if necessary, top up the ATF.