Removing and Mounting Transmission
Removing and mounting transmission
Preliminary work
Preliminary work for removing the transmission
Information:
^ The adaptation values must be reset using the Porsche System Tester when the transmission is renewed/replaced.
1. Unscrew two screws on the underside of the converter bell housing in the installed transmission.
2. Remove engine, please refer to: Vehicle/ Engine, Cooling and Exhaust/ Engine/ Service and Repair
Removing transmission
Overview of removing/mounting transmission
Information:
^ Shift lever on the transmission is in position P. Move lever up fully.
Information:
^ A second fitter is required!
1. Unscrew cardan shaft bolts -arrow- to the transfer gear. Counter with special counterer -3435- on triangular flange -A-.
Front cardan shaft to transfer gear
2. Remove fastening screws securing right heat shield to the transmission.
Right heat shield
Warning:
Danger of scalding and chemical burns from hot ATF
-> Allow ATF to cool down
-> Wear personal protective gear (goggles, gloves)
Information:
^ The line connections on the transmission and the ends of the ATF lines should be closed off after the lines have been separated from the transmission!
3. Disconnect ATF lines from the transmission. To do this, unscrew screw -arrow- and remove lines.
ATF line to transmission
4. Release vent lines from the retainers -arrow- on the engine.
Vent lines
5. Remove catalytic converter on left side.
6. Remove reference mark sender on the converter bell housing -arrow-.
Reference mark sender
7. Unscrew two coolant pipe screws on converter bell housing -arrow-.
Coolant pipes to converter bell housing
8. Remove stopper used to seal the converter assembly opening.
Removing stopper used to seal the converter assembly opening
9. Remove converter bolts:
10. Turn crankshaft clockwise with special tool socket wrench insert -9714-.
11. Insert special tool fixing pin -9595- into the front bore on the converter bell housing -arrow- and hold upwards with light pressure until it engages when the crankshaft is turned.
Disconnecting converter screws
12. Insert special tool Insert bit -9688- through opening in the engine block on converter screw. Connect special tool insert -9687-.
Opening for converter screws
13. Unscrew converter screw and twist out.
Unscrewing converter screws
14. Complete the steps described above for the other five screws.
15. Attach transmission with holder suspending device -2024 A - on workshop crane.
Transmission to workshop crane
16. Raise transmission a few centimeters and notch transmission cross member B -A-.
Transmission cross member
17. Unscrew engine transmission flange screws -arrows- and two screws on the underside.
Fastening screws securing transmission to engine
18. Uncouple transmission from engine.
Mounting transmission
Overview of removing/mounting transmission
Warning:
Danger of scalding and chemical burns from hot ATF
-> Allow ATF to cool down
-> Wear personal protective gear (goggles, gloves)
Information:
^ Since locking is not possible after removal, the cardan shaft can only be tightened to the specified torque after the engine has been installed.
^ Screws which are tightened with a torque angle must be replaced with new ones.
1. Fix engine to the crankshaft with special tool fixing pin -9595-.
Disconnecting the crankshaft
2. Attach transmission with holder suspending device -2024 A- on workshop crane.
Transmission to workshop crane
3. Insert special tool centering pin -9689- in converter.
Torque converter centering pin
4. Mount the transmission onto the engine.
5. Screw in engine transmission flange screws -arrows-. -> Tightening torque: 80 Nm (59 ftlb.)
Transmission to engine screw connection
Information:
^ Screws which are tightened with a torque angle must be replaced with new ones.
6. Raise transmission a few centimeters and install transmission cross member on holder -A-. -> Initial tightening: 50 Nm (37 ftlb.) -> Final tightening: 90 angular °
Transmission cross member
7. Disassemble workshop crane and holder suspending device -2024 A-.
8. Remove special tool centering pin -9689- through opening in the engine block.
Information:
^ A second fitter is required.
^ Replace converter screws.
9. Screw in new converter screws:
10. Place screw on special tool insert bit -9688- and screw in screw.
Opening for converter screw on engine
11. Position bit snap-on head and special tool insert -9687- and screw in screw, but do not tighten.
12. Turn crankshaft clockwise with special tool socket wrench insert -9714-.
13. Insert special tool fixing pin -9595- into the front bore on the converter bell housing -arrow- and hold with light pressure until it engages when the crankshaft is turned. This sets the position for the next screw.
Disconnecting converter screws
14. Complete the steps described above for the other five screws.
15. Remove special tool fixing pin -9595- before tightening the converter screws to the specified torque. Tightening torque: 85 Nm (63 ftlb.)
16. Insert stopper for converter assembly opening. To do this, moisten the groove on the stopper with water.
Stopper used to seal converter opening
17. Starting at the cut-out in the engine block -1-, press in the stopper all the way round from position -2-3-.
Stopper
18. 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
19. Fasten coolant pipe on the converter bell housing -arrow-. -> Tightening torque: 9 Nm (6.5 ftlb.)
Coolant pipes to converter bell housing
20. Install reference mark sender on the converter bell housing -arrow-. -> Tightening torque: 10 Nm (7.5 ftlb.)
Reference mark sender
21. Install catalytic converters on left side.
22. Press vent lines in the retainers -arrow- on the engine.
Vent lines to engine holder
23. Tighten the fastening screws in cardan shaft -arrow- to the transfer gear.
Front cardan shaft to transfer gear
24. Fasten ATF lines with new sealing rings on the transmission. -> Tightening torque: 25 Nm (19 ftlb.)
ATF line to transmission
Subsequent work
Subsequent work for refitting
Information:
^ The adaptation values must be reset using the Porsche System Tester when the transmission is renewed/replaced.
1. Install engine, please refer to: Vehicle/ Engine, Cooling and Exhaust/ Engine/ Service and Repair
2. Screw in two screws on the underside of the converter bell housing in the installed transmission.
3. Check and if necessary, top up the ATF.