Fluid Line/Hose: Service and Repair

Removing and installing line for ATF cooling











Information





Overview of ATF lines

1 - ATF cooler
2 - Retaining clip
3 - Aluminium screw, M8

When removing and installing ATF lines, make sure that the ATF lines are not strained. To avoid this, always loosen screws on both sides.

Preliminary work

1. Raise the vehicle at the prescribed jacking points.

Removing lines for ATF cooler

Warning
Hot fluid
Danger of scalding

- Let the fluid cool down.

- Wear personal protective gear.

Warning
Caustic fluid
Danger of chemical burns

- Avoid contact with caustic fluid.

- Wear personal protective gear.

- Ensure that there is good ventilation.

- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

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.





Transverse strut

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

3. Remove drive shafts on the transmission side.
3.1. Counter using special tool adapter plate 9510/1 (-1-).





Retaining tool for drive-shaft bolts

3.2. 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

4. 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.

5. Support the engine and lower the transmission.
5.1. Retainer plate 9769 (-1-) must be secured on the unit lifting platform using an M10 screw.





Engine mounting





Engine with unit lifting platform

5.2. 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

5.3. Remove left and right gear support and hydraulic mount.





Transmission support

C - Nut (never loosen)

5.3.1. Information: Do not loosen nuts -C-.
5.3.2. Unscrew screws -2- on the transmission supports -3-.





Gear support

5.3.3. Unscrew M8 nuts -1- between the body and hydraulic mount and remove transmission support with hydraulic mount -3-.
5.4. Lower the transmission.

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

6. Disconnect coolant hoses at the ATF cooler.





Coolant hoses at ATF cooler

6.1. Clamp coolant hoses.
6.2. 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-.
7. Remove ATF lines on transmission.





Holder for ATF lines

7.1. Loosen and unscrew screw -2- for clamping holder -1- on the Porsche Doppelkupplung and remove clamping holder -1-.
7.2. Pull ATF lines -3- out of the Porsche Doppelkupplung.





ATF cooler

8. Remove ATF cooler.
8.1. Unscrew screws -1- and remove ATF cooler -2- and ATF lines.
8.2. Remove ATF lines on ATF cooler.
9. Remove lines for ATF cooler.
9.1. Place oil collection pan underneath.





Holder for ATF lines on ATF cooler

9.2. Remove ATF lines on the ATF cooler.
9.2.1. Unscrew M6 x 12 screw -1- and pull out and remove ATF line -2- on the ATF cooler.
9.2.2. Unscrew M6 x 12 screw -3- and pull out and remove ATF line -4- on the ATF cooler.

Installing lines for ATF cooler

Warning
Hot fluid
Danger of scalding

- Let the fluid cool down.

- Wear personal protective gear.

Warning
Caustic fluid
Danger of chemical burns

- Avoid contact with caustic fluid.

- Wear personal protective gear.

- Ensure that there is good ventilation.

- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

1. Install lines for ATF cooler.





Holder for ATF lines on ATF cooler

1.1. Fit ATF lines on the ATF cooler.
1.1.1. Replace all O-rings.

Before installation, coat the O-rings with ATF oil.

1.1.2. Fit ATF line -4- on the ATF cooler and screw in and tighten M6 x 12 screw -3-.
1.1.3. Fit ATF line -2- on the ATF cooler and screw in and tighten M6 x 12 screw -1-.

Always use new aluminium screws. Blow out threaded bore thoroughly with compressed air.

Tighten M6 screw at "medium" setting.

- Tightening torque: 2.4 Nm (2 ftlb.)





ATF cooler

2. Fit ATF cooler.
2.1. Screw in and tighten screws -1-.

Always use new aluminium screws. Blow out threaded bore thoroughly with compressed air.

Tighten M6 screws at "medium" setting.

- Tightening torque: 2.4 Nm (2 ftlb.)

3. Fit ATF lines on transmission.





Holder for ATF lines

3.1. Press ATF lines -3- into the Porsche Doppelkupplung.
3.2. Fit clamping holder -1- and screw in and tighten screw -2- on the Porsche Doppelkupplung using an electronic torque wrench 9768.

Always use new aluminium screws. Blow out threaded bore thoroughly with compressed air.

Tighten M8 screws at "medium" setting.

- Tightening torque: 6 Nm (4.5 ftlb.)

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. Install transmission holder.
5.1. Raise the transmission.

Hydraulic garage jack H 2 SL WE 1032





Gear support

5.2. 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

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





Engine mounting

6. 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.)

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

- Tightening torque: 81 Nm (60 ftlb.)





Drive shaft

8. 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.)

9. Install support plate.





Support plate

9.1. 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.)

9.2. 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. Check and top up ATF.