Removing and Installing Transmission
Removing and installing transmission
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 rear silencer.
Removing transmission
Danger
Vehicle can fall down
Risk of squashing or crushing
Risk of damage to the vehicle
- Do not place any solid objects under the raised vehicle.
- Ensure that the lifting platform is prevented from lowering.
- Remove solid objects before lowering the vehicle.
- Raise the vehicle only at the take-up points provided.
Information
The fastening nuts of the transmission support must never be loosened at the hydraulic mount because otherwise the transmission brackets will be damaged.
Information
The clutch pedal must not be pressed if the clutch slave cylinder has been removed. Danger of injury from the push rod which can be pressed out of the slave cylinder hydraulically. Affix a warning note in the vehicle!
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 anti-roll bar.
Loosen screws between the anti-roll bar and rear-axle carrier side section -arrows- and fold anti-roll bar forward.
Anti-roll bar
3. Remove drive shafts.
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.
Drive shaft
Information
Protect drive shafts against mechanical damage (e.g. with a rubber hose that has been cut open).
4. Disconnect reversing light switch.
Pull off cable plug -arrow- for reversing light switch.
Reversing light switch
5. Disconnect shift and select cables at the transmission.
Shift and selector cables
Lever shift cable (with grey sealing cap) -1- and selector cable (with blue sealing cap) -2- off the ball pin and disengage from the support bracket.
6. Remove cross member.
Cross member
Unscrew screws -arrows- on the cross member and remove cross member.
7. Support the engine and lower the transmission.
7.1. Retainer plate 9769 -1- must be secured on the unit lifting platform using an M10 screw.
Engine mounting
Engine with unit lifting platform
7.2. 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
7.3. Remove left and right gear support and hydraulic mount.
7.3.1. Information: Do not loosen nuts -C-.
Transmission support
C - Nuts (never loosen)
7.3.2. Unscrew screws -2- on the transmission supports -3-.
Gear support
7.3.3. Unscrew M8 nuts -1- between the body and hydraulic mount and remove transmission support with hydraulic mount -3-.
7.4. Lower the transmission for better access when removing the clutch slave cylinder.
8. Remove clutch slave cylinder.
8.1. Loosen and unscrew nut -arrow- on external shift mechanism.
External shift mechanism
8.2. Remove external shift mechanism.
Pulling off external shift mechanism
Pull external shift mechanism off the shifting shaft using pole terminal pull-off device Nr.99 or puller 9736.
8.3. Remove clutch slave cylinder.
Unscrew M8 screw -arrow- between the clutch slave cylinder and transmission and remove the clutch slave cylinder. Do not disconnect clutch line while doing this.
Clutch slave cylinder
Caution
Mechanical overload of components
Component will be damaged irreparably
- Observe guidelines for assembly and disassembly
9. Remove transmission.
9.1. First loosen and unscrew M12 x 55 screws -1, 2-, then -6, 5, 3- and finally -4-.
Porsche Doppelkupplung screws
9.2. Remove the transmission by guiding it down and towards the rear.
Installing transmission
Information
Before installing the transmission, clean splines of transmission input shaft and grease lightly, e.g. with Olista Longtime 3 EP.
Caution
Mechanical overload of components
Component will be damaged irreparably
- Observe guidelines for assembly and disassembly
1. Install transmission.
1.1. Screw in and tighten screws -4- first, then -3, 5, 6- and finally -1,2-.
Porsche Doppelkupplung screws
- Tightening torque: 85 Nm (63 ftlb.)
2. Install clutch slave cylinder.
2.1. Guide the clutch slave cylinder into the opening on the transmission and screw in M8 screw.
Clutch slave cylinder
- Tightening torque: 23 Nm (17 ftlb.)
Information
Before installing the clutch slave cylinder, grease the push rod with Kluberalfa in the area of the release-lever ball socket. Part No. 000.043.304.02 (50g tube).
2.2. Fit external shift mechanism and screw on M8 nut.
- Tightening torque: 23 Nm (17 ftlb.)
Fastening nut
3. Install transmission holder.
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-.
- Tightening torque: 65 Nm (48 ftlb.)
- 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 into position and screw in and tighten M8 x 40 screws arrows-.
- 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.
Cross member
Fit cross member and screw in and tighten M10 x 72 screws -arrows-.
- Tightening torque: 65 Nm (48 ftlb.)
7. Connect shift and selector cables.
Shift and selector cables
Engage shift cable (with grey sealing cap) -1- and selector cable (with blue sealing cap) -2- in the support bracket and press them onto the ball pin.
8. Connect cable plug for reversing light switch.
Reversing light switch
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. Install rear silencer.
2. Mount wheels.
3. Check and if necessary top up transmission oil.
4. Lower the vehicle.