Removing and Installing Porsche Doppelkupplung (PDK)

Removing and installing Porsche Doppelkupplung (PDK)











Preliminary work

Danger
Vehicle raised incorrectly
Danger of fatal injury and material damage should the vehicle fall down

- Jack the vehicle at the prescribed jacking points.

Caution
Hot components
Risk of burns

- Let hot components cool down.

- Wear personal protective gear.

1. Jack and raise the vehicle at the prescribed jacking points.

Information
Take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points.

2. Remove wheels.
3. Remove underbody panelling.
4. Remove rear silencer.

Removing Porsche Doppelkupplung (PDK)

Information
Take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points.

1. Remove support plate.





Support plate

1.1. Remove diagonal braces.

Unscrew M10/M12 screws and M10 nuts and remove diagonal braces -1-.

1.2. Remove support plate.

Unscrew M10 x 25 screws and M10 nuts and remove support plate -2-.

2. Remove cross member.





Cross member

Unscrew M10 x 70 screws -1- and remove cross member -2-.

3. Remove parking lock cable on the Porsche Doppelkupplung.





Parking lock cable

3.1. Press ball joint of parking lock cable -1- off the parking lock lever.
3.2. Release parking lock cable -1- at the bracket by pressing the locking lugs -arrows- together and pull it out.
4. Remove drive shafts on the transmission side.
4.1. Counter using special tool adapter plate 9510/1 (-1-).





Retaining tool for drive-shaft bolts

4.2. Unscrew the six bolts between the drive shaft and transmission flange.

Information
Protect drive shafts against mechanical damage (e.g. with a rubber hose that has been cut open).





Drive shaft

5. Remove anti-roll bar on rear-axle carrier side section.





Anti-roll bar

Unscrew M8 x 40 screws -1- and move anti-roll bar -2- into position.

6. Support the engine and lower the transmission.
6.1. Retainer plate 9769 -1- must be secured on the unit lifting platform using an M10 screw.





Engine mounting

6.2. Position unit lifting platform -1- under the vehicle, 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 lifting platform -1- must be positioned slightly diagonally -3- using the adjustment controls so that the bores are directly parallel.

- Adjustment value: 10 degrees





Engine with unit lifting platform

6.3. Remove left and right gear support and hydraulic mount.
6.3.1. Information: Do not loosen nuts -C-.





Transmission support

C - Nut (never loosen)





Gear support

6.3.2. Unscrew screws -2- on the transmission supports -3-.
6.3.3. Unscrew M8 nuts -1- between the body and hydraulic mount and remove transmission support with hydraulic mount -3-.
6.4. Lower the transmission.

Only lower the transmission sufficiently to allow access to the cable connections and coolant hoses.

7. Disconnect electric multiple plug connector on the Porsche Doppelkupplung.
7.1. Release and pull off the bayonet lock on the electric multiple plug connectors -1-.





Electric multiple plug connector

7.2. Detach clip holders -arrows- with electric lines -2- on the transmission and lay electric lines -2- aside.
8. Disconnect coolant hoses at the ATF cooler.





Coolant hoses at ATF cooler

8.1. Clamp coolant hoses.
8.2. Disconnect coolant hoses -1- by releasing the spring band clamps -2- using a pair of angled spring band pliers -3- and pull off coolant hoses -1-.
9. Remove the speed sender.





Removing and fitting speed sender

Unscrew M6 x 15 screw -1-, remove speed sender -2- and place it safely aside.

10. Remove holder with solenoid valve for disc valve.





Cable plug for solenoid valve

10.1. Disconnect cable plug -1-.
10.2. Unscrew M6 x 12 screw -2- and position solenoid valve -3-.

Caution
Mechanical overload of components
Component will be damaged irreparably

- Observe guidelines for assembly and disassembly

11. Remove Porsche Doppelkupplung.
11.1. Loosen and unscrew M12 x 55 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 guiding it towards the rear.

Installing Porsche Doppelkupplung (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.

Information
The aluminium screws on the Porsche Doppelkupplung must be tightened according to a yield strength-controlled tightening procedure using an electronic torque wrench 9768.

To ensure that the screws are tightened uniformly, the corresponding tightening setting "light, medium or hard" must always be used.

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:

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 holder with solenoid valve for disc valve.





Cable plug for solenoid valve

2.1. Fit solenoid valve -3- and screw in and tighten M6 x 12 screw -2-.

- Tightening torque: 10 Nm (7.5 ftlb.)

2.2. Connect cable plug -1-.
3. Fit the speed sender.

Fit speed sender -2- and screw in and tighten M6 x 15 screw -1-.

- Tightening torque: 10 Nm (7.5 ftlb.)





Removing and fitting speed sender

4. Connect coolant hoses at the ATF cooler.





Coolant hoses at ATF cooler

4.1. Connect coolant hoses -1- by releasing the spring band clamps -2- using a pair of angled spring band pliers -3- and securing them on the coolant hoses -1-.
4.2. Remove hose clamps.
5. Connect electric multiple plug connector to the Porsche Doppelkupplung.
5.1. Release and pull off the bayonet lock on the electric multiple plug connectors -1-.





Electric multiple plug connector

5.2. Route electric lines -2- and secure on the transmission -arrows-.
6. Install gear support.
6.1. Raise the transmission.

Hydraulic garage jack H 2 SL WE 1032





Gear support

6.2. Install left and right gear support and hydraulic mount.

Fit gear support -3- and hydraulic mount. Screw on and tighten M8 nuts -1- on hydraulic mounts and M10 screws -2- on gear support -3-.

- Tightening torque: 65 Nm (48 ftlb.)

- Tightening torque: 33 Nm (24 ftlb.)





Engine with unit lifting platform

6.3. Lower and remove transmission jack.
6.4. Lower the unit lifting platform -1-, reset it to zero position and remove it.
6.5. Retainer plate 9769 (-1-) must be removed from the unit lifting platform.





Engine mounting

7. Fit anti-roll bar on rear-axle carrier side section.

Move anti-roll bar -2- into position and screw in and tighten M8 x 40 screws -1-.





Anti-roll bar

- Tightening torque: 23 Nm (17 ftlb.)

8. Fit drive shafts on the transmission side.
8.1. Counter using special tool adapter plate 9510/1 (-1-).





Retaining tool for drive-shaft bolts

8.2. Screw in and tighten the six M10 bolts between the drive shaft and transmission flange.





Drive shaft

- Tightening torque: 81 Nm (60 ftlb.)

9. Engage parking lock cable on the Porsche Doppelkupplung.





Parking lock cable

9.1. Check that the gear selector on the selector support is in position "P" and is locked.
9.2. Check that the transmission parking lock is fully engaged.
9.3. Fit the parking lock cable -arrow- on the bracket, press it in and engage it.
9.4. Press ball joint of parking lock cable -1- onto the parking lock lever.

Note: The parking lock cable must only be connected without preload.

10. Install the transverse strut.





Transverse strut

Fit cross member -2- and screw in and tighten M10 x 72 screws -1-.

- Tightening torque: 65 Nm (48 ftlb.)

11. Install support plate.





Support plate

11.1. Install support plate.

Fit support plate -2- and screw in and tighten M10 x 25 screws and M10 nuts.

- Tightening torque: 65 Nm (48 ftlb.)

- Tightening torque: 65 Nm (48 ftlb.)

11.2. Install diagonal braces.

Fit diagonal braces -1- and screw in and tighten M10/M12 screws and M10 nuts.

M10

- Tightening torque: 65 Nm (48 ftlb.)

M12

- Tightening torque: 110 Nm (81.5 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. Mount wheels.
4. Install underbody panelling.