Case: Service and Repair
Removing and installing assembly cover
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.
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 rear silencer.
Removing assembly cover
Overview of assembly cover
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 parking lock cable on the Porsche Doppelkupplung.
Parking lock cable
2.1. Press ball joint of parking lock cable -1- off the parking lock lever.
2.2. Release parking lock cable -1- at the bracket by pressing the locking lugs -arrows- together and pull it out.
3. Remove cross member.
Unscrew M10 x 70 screws -1- and remove cross member -2-.
Transverse strut
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
The sealing ring for the long halfshaft flange cannot be replaced while the long halfshaft flange is still installed. In the event of leaks, the sealing ring must always be replaced together with the mounting saddle.
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
Engine with unit lifting platform
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
6.3. Remove left and right gear support and hydraulic mount.
C - Nut (never loosen)
Transmission support
6.3.1. Information: Do not loosen nuts -C-.
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. Remove exhaust system suspension.
Exhaust system suspension
Loosen and unscrew M8 screws and remove suspension.
8. Pull out assembly cover.
Assembly cover
8.1. Screw tapping screws into the assembly cover.
8.2. At the same time, pull out the assembly cover using the claw sleeve from the slide hammer kit Nr.168.
Installing assembly cover
1. Drive in assembly cover.
Assembly cover
1.1. Coat assembly cover lightly with fresh transmission oil.
1.2. Fit assembly cover on the transmission housing -1- and use pressure piece T10180, -2- to drive it in evenly until the collar of the assembly cover is flush with the housing.
Notice
Incorrect handling of sealing rings and covers
Leaks
Risk of damage to components
- Use clean tools without burrs.
- Make sure not to leave any scores or scratches when cleaning.
2. Install exhaust system suspension.
Exhaust system suspension
Fit suspension and screw in and tighten M8 screws.
- Tightening torque: 45 Nm (33 ftlb.)
3. Install gear support.
3.1. Raise the transmission.
Hydraulic garage jack H 2 SL WE 1032
Gear support
3.2. 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-.
M10
- Tightening torque: 65 Nm (48 ftlb.)
M8
- Tightening torque: 33 Nm (24 ftlb.)
Engine with unit lifting platform
3.3. Lower and remove transmission jack.
3.4. Lower the unit lifting platform -1-, reset it to zero position and remove it.
3.5. Retainer plate 9769 (-1-) must be removed from the unit lifting platform.
Engine mounting
4. Fit anti-roll bar on rear-axle carrier side section.
Anti-roll bar
Move anti-roll bar -2- into position and screw in and tighten M8 x 40 screws -1-.
- Tightening torque: 23 Nm (17 ftlb.)
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 M10 bolts between the drive shaft and transmission flange.
- Tightening torque: 81 Nm (60 ftlb.)
Drive shaft
6. 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.)
Parking lock cable
7. Engage parking lock cable on the Porsche Doppelkupplung.
7.1. Check that the gear selector on the selector support is in position "P" and is locked.
7.2. Check that the transmission parking lock is fully engaged.
7.3. Fit the parking lock cable -arrow- on the bracket, press it in and engage it.
7.4. Press ball joint of parking lock cable -1- onto the parking lock lever.
Note: The parking lock cable must only be connected without preload.
8. Install support plate.
Support plate
8.1. 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.)
8.2. 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. Install rear silencer.
2. Check oil for final drive and top up if necessary.