Removing and Installing Porsche Double Clutch (PDK)
Removing and installing Porsche Double Clutch (PDK)
Preliminary work for removing and installing Porsche Double Clutch (PDK)
Preliminary work for Porsche Double Clutch (PDK)
1. Remove front underbody panelling.
2. Remove center underbody panelling.
3. Remove exhaust system.
4. Remove cardan shaft.
5. Remove catalytic converter.
Removing Porsche Double Clutch (PDK)
1. Support transmission with transmission jack.
2. Remove heat protection on the transmission.
Heat protection panel for PDK wiring harness
3. Disconnect connector on the transmission by turning it 1/4 turn to the left.
Connector on PDK wiring harness
4. In conjunction with all-wheel drive: Impact puller 9799 must be fitted at the groove in the connecting shaft using four screws -1-.
Fitting tool
5. In conjunction with all-wheel drive: Remove connecting shaft from the all-wheel final drive using impact puller 9799. This pushes the connecting shaft into the PDK transmission.
Removing and fitting connecting shaft
6. Place a drip pan underneath.
WARNING
Hot fluid
* Danger of scalding
-> Let the fluid cool down.
-> Wear personal protective gear.
7. Disconnect ATF line at the transmission.
ATF line on transmission
8. Press locking cable off the gearshift lever using a disassembly tool Nr.21.
Removing locking cable
9. Press fastening part on the locking cable up and pull it backwards out of the support.
Removing cable from support
Information
The ATF pan must cover the complete surface of the transmission jack.
If this is not the case, the gap at the ATF pan must be filled with a suitable object (piece of wood).
10. Support transmission with a transmission jack and secure with a retaining strap.
11. Unscrew fastening screws from transmission support.
Transmission support to body
12. Unscrew fastening screws for securing transmission to engine.
PDKit on engine
13. Remove transmission.
Installing Porsche Double Clutch (PDK)
1. Coat shaft teeth on the PDK with Longtime 3EP.
Greasing shaft teeth
2. In conjunction with 2WD: Fit transmission with a spacer plate and mount it on the engine by turning the output shaft.
PDK spacer plate
3. In conjunction with all-wheel drive: Fit transmission and mount it on the engine by turning the output shaft.
4. Screw in new fastening screws for securing transmission to engine. -> Initial tightening: 38 Nm (28 ftlb.) -> Torque angle: 90 degrees
PDKit on engine
5. Screw in fastening screws on transmission support. -> Tightening torque: 65 Nm (48 ftlb.)
Transmission support on body
6. Slide fastening part for locking cable into support on the transmission in direction of travel.
Locking cable on support
7. Press locking cable onto ball joint on transmission.
Fitting locking cable
8. In conjunction with all-wheel drive: Replace circlip -1- on input flange on all-wheel final drive.
Circlip on all-wheel flange
9. In conjunction with all-wheel drive: Coat input flange on all-wheel final drive lightly with Anti Seize -arrow-.
Circlip on all-wheel flange
10. In conjunction with all-wheel drive: Impact puller 9799 must be fitted at the groove in the connecting shaft using four screws -1-.
Fitting tool
11. In conjunction with all-wheel drive: Attach connecting shaft to the all-wheel final drive and fit using impact puller 9799 until the ring -1- is visible on the transmission.
Removing and fitting connecting shaft
Attaching transmission
12. Replace sealing rings at the ends of the ATF line.
Sealing rings on ATF line
13. Screw in fastening screws securing ATF line to transmission.
ATF line on transmission
14. Secure connector on the transmission by turning it 1/4 turn to the right.
Connector on PDK wire harness
15. Fit heat protection on the transmission.
Heat shield for PDK wire harness
Subsequent work for removing and installing Porsche Double Clutch (PDK)
Subsequent work for Porsche Double Clutch (PDK)
1. Install catalytic converter.
2. Install cardan shaft.
3. Install exhaust system.
4. Check ATF.
5. Adjust the locking cable.
6. Install front underbody panelling.
7. Install center underbody panelling.