A/T - PDK Transmission Diagnosis/Symptoms/Repair
Service3
35/09 ENU 3730
Jun 28, 2010
The present document was valid at the time of print. A later version may be available online
PDK Transmission Diagnosis, Symptoms and Repair Procedures
(35/09)
Tools
Model year:
as of 2009
Information
This Technical Information replaces the TI dated May 17, 2010. Changes/additions compared to the previous Technical Information:
--> Information added under "Procedure: 2 - Repair measures in the event of leaks on the PDK transmission":
"Information/Traces of oil around the oil pan seal "added under item 13.
--> Information added under "Procedure: 4 - Procedure in the event of noises on the PDK transmission": Additional text ... (if possible) a video recording added under "document the information specified below in PQIS".
Information
Changes/additions compared to the previous Technical Information:
--> Step 1.4" and References" section now include the following link: 373000 PDK transmission in limp-home mode: Fault codes P1552, P1990 and/or P1991 (77/09).
Vehicle Type:
Boxster (987)/Boxster S (987)
Cayman/Cayman S
Equipment:
Porsche Doppelkupplung (PDK) - I-no. 250
Concerns:
PDK transmission/control unit for PDK transmission
Information:
Procedure and repair measures in the event of complaints relating to PDK:
^ Gearbox emergency operation/other warning messages
^ Fault memory entries in the fault memory of the PDK control unit
^ Leaks on the PDK transmission
^ Complaints relating to comfort
^ Complaints relating to noises
Information
^ Always create a Vehicle Analysis Log (VAL) before starting any measures.
^ Make sure that you are using the latest version of the PIWIS Tester 9718 software (i.e. version 27.000 or higher).
^ If components are replaced: Return components to Porsche and document all measures in PPN.
Information
The following procedure applies in relation to calibration:
Engine torque loss adaptation must always be performed before carrying out calibration (for details of procedure/conditions, see Step 3.6).
Essentially, calibration is required only after replacing parts or if you are expressly instructed to do so during troubleshooting.
A Calibration after part replacement routine ("major calibration routine") must always be carried out after replacing one of the following components:
- PDK control unit
- Electrohydraulic control unit
- PDK transmission
Calibration without previous part replacement ("minor calibration routine") must be carried out if you are expressly instructed to do so (e.g. during troubleshooting in the event of complaints relating to comfort).
When control unit programming is complete (DME/PDK - with or without part replacement), engine torque loss adaptation must be performed.
If a control unit was only re-programmed (without replacing parts), calibration is not required unless there are other faults present (e.g. problems relating to gearshift and drive-off quality) for which calibration is recommended in order to correct the faults.
Work Procedure:
1 Procedure and repair measures in the event of fault entries in the fault memory of the PDK control unit.
The required procedure for correcting faults for the groups of fault memory entries listed below is described using flow charts.
A separate flow chart is used for each of the fault groups specified below.
Information
You will find the flow charts under the heading "373O - Flow charts for PDK fault codes" in the information medium TI - Technical Information releases, main group 3 - Transmission.
Sequence for correcting faults if various fault entries from various fault groups are present:
1) Electrical faults
2) Gear skip/engagement block
3) Sensor faults/software faults
4) Gear selection faults
Fault correction for complaints relating to comfort and noise must only be carried out after the faults listed above (if present) have been found and corrected.
1.1 Electrical faults
Electrical faults include all fault memory entries relating to fault type
- Short circuit to ground
- Short circuit to B+
- Shunt
- Open circuit
- Incorrect voltage (operating limit, undervoltage, overvoltage)
Correct faults as shown in Flow chart EF - Electrical faults.
1.2 Gear skip/engagement block (fault memory entries P176x)
Gear skips/engagement blocks are identified by the fault memory entries 176x in the PDK control unit:
- P1764: Synchronization engagement blocks or gear skips
- P1768, P1769 and P176A... to P176F: Synchronization fault (gear cannot be engaged)
- P1760: Double faults
Correct faults as shown in Flow chart EB - Gear skip/engagement block - P176x.
1.3 Sensor faults/software faults
Sensor faults" include all fault memory entries relating to the components
- Distance sensor
- Speed sensor
- Pressure sensor
- Temperature sensor
Correct faults as shown in Flow chart SF0-SF5.
Overview of fault memory entries for distance sensor (Flow chart SF1)
-P1731... to P1734: Distance sensor information/shift rod faults (outside of validity range)
Overview of fault memory entries for speed sensor (Flow chart SF2)
- P0730: Transmission monitoring symptom - incorrect gear ratio
- P1743: Plausibility of transmission input shaft speed sensor clutch 1
- P1744: Plausibility of transmission input shaft speed sensor clutch 2
- P1745: Input shaft overspeed
Overview of fault memory entries for pressure sensor (Flow chart SF3)
- P0841 and P0846: Pressure sensor fault (measured value implausible)
- P17B1 and P17B2: Clutch fault (activation pressure implausible)
- P17B3 and P17B4: Clutch valve pressure stays too high mechanically during overlap switching after quick filling
- P17BB ... to P17BE: Clutch fault (clutch cannot be open)
Overview of fault memory entries for temperature sensor (Flow chart SF4)
- P0711: Transmission temperature sensor implausible
- P172D: Transmission temperature sensor gradient fault
- P17FO to P17F2: Transmission overtemperature fault
Overview of fault memory entries for software faults (Flow chart SF5)
- P0602: Control unit not programmed
- P0603: EEPROM emulation checksum incorrect
- P0604: RAM test failed
- P0605: Flash checksum incorrect
- P0614: Data status does not match engine
- P0702: Watchdog (Monitoring Unit)
- P1749: Variant coding invalid
- P1870: Data record for shift rod synchronization invalid
- P1871: Data record for clutch synchronization invalid
- P1872: Data record for HYTI synchronization invalid (HYTI = Hydraulic Teach In).
- P1897: Software monitoring: Calculation of speed control intervention by engine implausible
- P174B: Invalid allocation of control unit and transmission hardware (cross-installation)
- P174C: BIN file does not match software version
- P174E: EEPROM content at system start incorrect/implausible
- P186F: Data record for electric synchronization data invalid
- P189A ... to P189D: Software monitoring
- P18A0 ... to P18B5: Software monitoring
- Uxxxx: CAN fault
1.4 Overview of fault memory entries for gear selection
- P17D0... to 1 7D9: Hydraulic gear selection fault
- P1779, P177A ... to P177F: Synchronization fault (gear cannot be disengaged)
Other fault entries relating to the fault memory entries specified above that can be entered in the fault memory of the PDK control unit.
- P18B4: Software monitoring with fault type $24/$25/$26
- P1990, P1991: Engine torque intervention not possible (see also 373000 PDK transmission in limp-
home mode: Fault codes P1552, P1990 and/or P1991 (77/09))
Correct faults as shown in Flow chart GS.
Work Procedure:
2 Repair measures in the event of leaks on the PDK transmission
Work Procedure:
3 Remedial and repair measures in the event of complaints relating to comfort (gearshift and drive- off quality).
3.1 Create and save the Vehicle Analysis Log (VAL) using the PIWIS Tester.
3.2 Find and correct any faults that are present in other control units (DME, PSM, air conditioning, etc.).
3.3 Check both oil levels (clutch and transmission) and correct them if necessary 370235 Checking and topping up ATF (clutch fluid) and 399035 Checking and topping up oil for final drive (with transmission oil).
Information
If implausible test results are obtained (e.g. clutch fluid level too low and transmission oil level too high) and/or if fault memory entries are present in the PDK control unit, these faults must first be found and corrected as shown in the relevant flow chart.
3.4 Read out the data version of the PDK control unit (PIWIS Tester> PDK control unit Identification menu item).
- If the PDK data version is < "T082" --> Re-program the DME and PDK control unit using the PIWIS
Tester and installed test software version 27.000 (or higher). Then continue with Step 3.5.
- If the PDK data version is >= "T082" --> Continue with Step 3.5.
3.5 Teach the throttle valve using the PIWIS Tester:
Select PIWIS Tester > DME control unit >> menu item System adaptation" Throttle valve adaptation" function.
3.6 Perform engine torque loss adaptation.
Conditions/procedure for engine torque loss adaptation:
^ Engine temperature is at least 80°C.
^ All loads switched off.
^ PDK selector lever in position P.
^ Allow engine to run at idle speed for 3 minutes with air conditioning switched off.
Then allow engine to run at idle speed for 3 minutes with air conditioning switched on (high load).
^ Switch off ignition and wait 15 seconds (adaptation values are stored).
3.7 Calibrate PDK by carrying out minor calibration routine ("Calibration without previous part replacement"):
Select PIWIS Tester > PDK control unit >> menu item Calibration" >> Calibration without previous part replacement" function.
3.8 Create and save the Vehicle Analysis Log (VAL) using the PIWIS Tester.
3.9 Perform adaptation drive. During the adaptation drive, change gear at least 30 times initially (in M" or "D").
3.10 Perform touchpoint adaptation.
Conditions/procedure for touchpoint adaptation:
^ At least 30 gear changes (in "M" or "D" were carried out previously while driving the vehicle.
^ Stop the vehicle on a level surface, but do not switch off the engine.
^ Position steering wheel straight ahead.
^ Do not switch any loads on or off.
^ Hold the vehicle for three minutes in transmission range "D" with the foot brake pressed firmly. Do not press the accelerator pedal.
^ Switch off ignition for at least 15 seconds (adaptation values are stored).
3.11 Continue the adaptation drive and again change gear at least 30 times (in "M" or "D").
3.12 Repeat touchpoint adaptation (Step 3.10) once.
3.13 Continue the adaptation drive using the gears and rev ranges specified below and observe any other specifications.
3.13.1 Accelerate to rev range 1,700 rpm in 5th gear.
Maintain rev range 1,700 rpm - 3,000 rpm in 5th gear with a low operating load for three minutes.
3.13.2 Then, accelerate to rev range 1,700 rpm in 6th gear.
Maintain rev range 1,700 rpm - 3,000 rpm in 6th gear with a low operating load for three minutes.
3.14 End the adaptation drive.
3.15 Create and save the Vehicle Analysis Log (VAL) using the PIWIS Tester.
3.16 Leave the vehicle overnight if necessary and evaluate it again with regard to gearshift/drive-off quality the next day.
^ If the vehicle checks out OK with regard to gearshift/drive-off quality --> End of remedial action.
^ If the vehicle does not show any improvement with regard to gearshift/drive-off quality, please contact your importer to find out what to do next.
Work Procedure:
4 Procedure in the event of noises on the PDK transmission.
If a complaint is received in relation to noises from the PDK transmission, please complete the following steps initially:
4.1 Create and save the Vehicle Analysis Log (VAL) using the PIWIS Tester.
4.2 Check to see if the noise is actually coming from the transmission.
4.3 Check how comparable vehicles behave in identical situations.
4.4 Check oil levels (clutch fluid and transmission oil level) and correct them if necessary
370235 Checking and topping up ATF (clutch fluid) and 399035 Checking and topping up oil for final drive (with transmission oil).
Information
If implausible test results are obtained (e.g. clutch fluid level too low and transmission oil level too high) and/or if fault memory entries are present in the PDK control unit, these faults must first be found and corrected as shown in the relevant flow chart.
4.5 Read out the data status of the PDK control unit (PIWIS Tester > PDK control unit >> menu item "Identification").
- If the PDK data status is < "T079" --> Re-program the DME and PDK control unit using the PIWIS Tester with test software version 25.000 (or higher) installed. Then continue with Step 4.6.
- If the PDK data status is >= "TO79" --> Continue with Step 4.6.
4.6 Teach the throttle valve using the PIWIS Tester:
Select PIWIS Tester > DME control unit >> menu item "System adaptation" >> "Throttle valve adaptation" function.
4.7 Perform engine torque loss adaptation.
Conditions/procedure for engine torque loss adaptation:
^ Engine temperature is at least 80°C.
^ All loads switched off.
^ PDK selector lever in position P.
^ Allow engine to run at idle speed for 3 minutes with air conditioning switched off.
^ Then allow engine to run at idle speed for 3 minutes with air conditioning switched on (high load).
^ Switch off ignition and wait 15 seconds (adaptation values are stored).
If, after carrying out tests and/or correcting faults, the vehicle still has definite symptoms in relation to transmission noises, please document the information specified below in PQIS:
^ Create a sound file of the noise or (if possible) a video recording with sound, which also shows the rev counter and the gear indicator.
^ Provide a detailed description of the noise (e.g. rattling, grinding, whining, whistling, singing, ...)
^ In which rev range does the noise occur?
^ In which gear does the noise occur?
^ At what speed does the noise occur?
^ In which load condition does the noise occur (traction, overrun, part load, full load)?
^ In which operating state does the noise occur (cold, warm)?
^ Exactly who noticed the noise (customer, workshop)?
^ What work has already been done?
Contact your importer to find out what to do next.
References:
Technical Information releases
--> 033500 Vehicle Analysis Log (VAL) (15/08)
--> 373000 PDK transmission in limp-home mode: Fault codes P1552, P1990 and/or P1991 (77/09)
--> 375500 PDK transmission: Modified oil drain plug (23/09)
Workshop Manual
--> 370235 Checking and topping up ATF (clutch fluid)
--> 399035 Checking and topping up oil for final drive (with transmission oil)
--> 373019 Removing and installing transmission control unit (PDK)
--> 387719 Removing and installing electrohydraulic control unit
--> 373419 Removing and installing Porsche Doppelkupplung (PDK)
987110, 987111, 987120, 987121, 987310, 987311, 987320,987321,997110, 997111, 997120, 997121, 997310, 997311, 997320, 997321, 997410, 997411, 997430, 997431, 997510, 997511, 997520, 997521, 997610, 997611, 997620, 997621
Model year as of 2009
C02, C36