Removing and Installing Porsche Doppelkupplung (PDK)
Removing and installing Porsche Doppelkupplung (PDK)
Preliminary work
1. Disconnect the battery.
2. Raise the vehicle at the prescribed jacking points.
3. Remove underbody panelling.
Removing Porsche Doppelkupplung (PDK)
Danger
Vehicle can fall down
Risk of squashing or crushing
Risk of damage to the vehicle
- Do not place any solid objects under the raised vehicle.
- Ensure that the lifting platform is prevented from lowering.
- Remove solid objects before lowering the vehicle.
- Raise the vehicle only at the take-up points provided.
Information
Take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points.
1. Remove the transverse strut.
Removing and installing cross member
Unscrew screws -2- (M10 x 40) and remove transverse strut -1-.
2. Remove the diagonal braces.
Removing and installing diagonal braces
Unscrew screws -2- (M12 x 30) on the cross member and screws -2- (M10 x 40) on the body and remove diagonal braces -1-.
3. Remove cross member.
Removing and installing cross member
Loosen nuts -1- on the bottom screws (M12 x 80) and unscrew screws; top screws (M12 x 80) only need to be loosened, due to existing slots; remove cross member -2-.
Top mounting for rear cross member
4. Disconnect electric multiple plug connector on the Porsche Doppelkupplung.
4.1. Turn the bayonet lock on the top electric multiple plug connector -1- to release it and pull it off.
Top Porsche Doppelkupplung connector
4.2. Turn the bayonet lock on the bottom electric multiple plug connector -1- to release it and pull it off.
Remove cable for electric multiple plug connector -1- from the cable guide -2-.
Bottom Porsche Doppelkupplung connector with cable guide
4.3. Disconnect cable plug on solenoid valve -1- for disc valve.
Cable plug for solenoid valve for Porsche Doppelkupplung
5. Remove the speed sender.
Removing and fitting speed sender
Unscrew screw -1-, remove speed sender -2- and place it safely aside.
6. Remove parking lock cable on the Porsche Doppelkupplung.
Removing parking lock cable
6.1. Press ball head of parking lock cable -1- off the parking lock lever.
6.2. Release parking lock cable -1- at the bracket by pressing the locking lugs -2- together and pull it out.
7. Remove drive shafts on the transmission side.
7.1. Counter using special tool adapter plate 9510/1 ( -1- ).
Retaining tool for drive-shaft bolts
7.2. Unscrew the six bolts between the drive shaft and transmission flange.
Drive shaft
Information
Protect drive shafts against mechanical damage (e.g. with a rubber hose that has been cut open).
Supporting engine with a unit elevating platform
8. Support the engine and lower the transmission.
8.1. Position unit elevating platform under the vehicle, secure retainer plate 9769 ( -2- ) on the unit lifting platform and insert the mounting pegs of the retainer plate 9769 ( -2- ) into the mounting bores on the engine and press in with a slight preload. The unit elevating platform must be positioned slightly diagonally using the adjustment controls so that the bores are directly parallel.
- Adjustment value: 10 degrees
8.2. Position transmission jack under the ATF pan of the Porsche Doppelkupplung and secure the PDK using a restraining strap. Make sure that the entire surface of the ATF pan is used as the contact surface so as to avoid damaging the ATF pan.
8.3. Remove gear support.
Removing and installing gear support
Unscrew M10 nuts -2-.
Unscrew M12 screw -3- and remove gear support -1-.
8.4. Lower the transmission.
Only lower the transmission sufficiently to allow access to the screws for the B+ cable duct and coolant pipes.
Information
When lowering and lifting the Porsche Doppelkupplung, make sure that the sharp cooling fins on the ATF cooler do not damage the left cooling water hose. Move left cooling water hose into position when lowering and lifting the PDK.
9. Remove B+ cable duct.
B+ cable routing on transmission
Remove B+ cable duct -1- by unscrewing the M6 screws -2- and taking out the B+ cable duct -1-.
10. Remove coolant lines and coolant hoses.
10.1. Pull off vacuum line -1- for brake booster.
Brake booster vacuum line
10.2. Close off coolant lines -1- by releasing and pulling off the safety clips on the Henn couplings -arrows-.
Disconnecting and connecting cooling water lines
10.3. Remove cooling water tubes -1- by unscrewing the M6 screws -2-.
Removing and fitting cooling water lines
Caution
Mechanical overload of components
Component will be damaged irreparably
- Observe guidelines for assembly and disassembly
11. Remove Porsche Doppelkupplung.
Sequence for loosening Porsche Doppelkupplung screws
11.1. Loosen and unscrew M12 screws first -1, 2-, then -6, 5, 3- and finally -4-.
Porsche Doppelkupplung screws
11.2. Lower the Porsche Doppelkupplung.
Lower the Porsche Doppelkupplung until it is approx.
- Control value: 10 mm from the anti-roll bar.
11.3. Remove Porsche Doppelkupplung by pulling it backwards and drain it.
Installing Porsche Doppelkupplung (PDK)
Information
When lowering and lifting the Porsche Doppelkupplung, make sure that the sharp cooling fins on the ATF cooler do not damage the left cooling water hose. Move left cooling water hose into position when lowering and lifting the PDK.
Information
If the vehicle is placed on its wheels or moved in the workshop, the rear cross member must always be refitted beforehand.
If the cross member is not refitted, the vehicle will have to be aligned after the engine or transmission is installed.
1. Install Porsche Doppelkupplung.
Information
After replacing the Porsche Doppelkupplung or after carrying out repairs in the Porsche Doppelkupplung, the transmission control unit must be programmed and calibrated using the PIWIS Tester 9718.
When replacing the Porsche Doppelkupplung, please note the following:
Sequence for loosening Porsche Doppelkupplung screws
Caution
Engine housing overload.
Risk of engine damage if housing breaks.
- Observe loosening and tightening sequence!
- Loosening sequence: Loosen screws from the bottom up.
- Tightening sequence: Tighten screws from top to bottom.
Information
Always replace flange screws.
1.1. Lift up and mount the Porsche Doppelkupplung.
1.2. Screw in and tighten screws -4- first, then -3, 5, 6- and finally -1, 2-.
Porsche Doppelkupplung screws
- Tightening torque: 85 Nm (63 ftlb.)
Caution
Engine housing overload.
Risk of engine damage if housing breaks.
- Observe loosening and tightening sequence!
- Loosening sequence: Loosen screws from the bottom up.
- Tightening sequence: Tighten screws from top to bottom.
2. Fit coolant lines and coolant hoses.
2.1. Connect vacuum line -1- for brake booster.
Brake booster vacuum line
2.2. Connect coolant lines -1- by locking the safety clips on the Henn couplings -arrows-.
Disconnecting and connecting cooling water lines
Information
The coolant hoses must engage audibly when pushed into the flanges (Henn coupling).
2.3. Fit cooling water tubes -1- by screwing in and tightening the M6 screws -2-.
Removing and fitting cooling water lines
- Tightening torque: 10 Nm (7.5 ftlb.)
3. Fit B+ cable duct.
Fit B+ cable duct -1- by screwing in and tightening the M6 screws -2-.
- Tightening torque: 10 Nm (7.5 ftlb.)
B+ cable routing on transmission
4. Install gear support and remove unit elevating platform.
4.1. Raise the transmission.
Information
When lowering and lifting the Porsche Doppelkupplung, make sure that the sharp cooling fins on the ATF cooler do not damage the left cooling water hose. Move left cooling water hose into position when lowering and lifting the PDK.
4.2. Install gear support.
Removing and installing gear support
Fit the gear support -1- and screw on and tighten M10 nuts -2-.
- Tightening torque: 65 Nm (48 ftlb.)
Screw in and tighten M12 screw -3-.
- Tightening torque: 120 Nm (89 ftlb.)
Supporting engine with a unit elevating platform
4.3. Lower and remove transmission jack -4-.
4.4. Lower the unit elevating platform -1-, reset it to zero position and remove it.
5. Fit drive shafts on the transmission side.
5.1. Counter using special tool adapter plate 9510/1 (-1-).
Retaining tool for drive-shaft bolts
5.2. Screw in and tighten the six bolts between the drive shaft and transmission flange.
Drive shaft
- Tightening torque: 81 Nm (60 ftlb.)
Information
Protect drive shafts against mechanical damage (e.g. with a rubber hose that has been cut open).
Engaging parking lock cable
6. Engage parking lock cable on the Porsche Doppelkupplung.
6.1. Check that the gear selector on the selector support is in position "P" and is locked.
6.2. Check that the transmission parking lock is fully engaged.
6.3. Fit the parking lock cable -1- on the bracket, press it in and engage it.
6.4. Press ball head of parking lock cable -1- onto the parking lock lever.
Note: The parking lock cable must only be connected without preload.
7. Fit the speed sender.
Removing and fitting speed sender
Fit speed sender -2- and screw in and tighten screw -1-.
- Tightening torque: 10 Nm (7.5 ftlb.)
8. Connect electric multiple plug connector to the Porsche Doppelkupplung.
8.1. Connect the bayonet lock on the top electric multiple plug connector -1-.
Top Porsche Doppelkupplung connector
8.2. Connect the bayonet lock on the bottom electric multiple plug connector -1-.
Bottom Porsche Doppelkupplung connector with cable guide
8.3. Connect cable plug on solenoid valve -1- for disc valve.
Cable plug for solenoid valve for Porsche Doppelkupplung
9. Install cross member.
Removing and installing cross member
Position cross member -2- and fit and tighten M12 x 80 screws -1-.
- Tightening torque: 110 Nm (81.5 ftlb.)
10. Install diagonal braces.
Fit diagonal braces -1-. Screw in and tighten screws -2- (M12 x 30) on the cross member and screws -2- (M10 x 40) on the body.
- Tightening torque: 100 Nm (74 ftlb.)
- Tightening torque: 65 Nm (48 ftlb.)
Removing and installing diagonal braces
11. Install the transverse strut.
Removing and installing cross member
Fit transverse strut -1- and screw in and tighten screws -2- (M10 x 40).
- Tightening torque: 65 Nm (48 ftlb.)
Subsequent work
1. Calibrate the Porsche Doppelkupplung control unit and erase the fault memory.
PIWIS Tester 9718
2. Check ATF and oil for final drive and top up if necessary.
3. Install underbody panelling.
4. Connect the battery.