373419 Removing and installing Porsche Doppelkupplung (PDK)
WM 373419 Removing and installing Porsche Double Clutch (PDK)
Tools
Technical values
Preliminary work
1. Disconnect the battery.
-> 2706IN Work instructions after disconnecting the battery
2. Raise the vehicle at the prescribed jacking points.
-> 4X00IN01 Lifting the vehicle
3. Remove underbody panelling.
-> 519419 Removing and installing cover for rear underbody - section on "Removing" 519419 Removing and Installing Cover for Rear Underbody-> 519319 Removing and installing cover for centre underbody - section on "Removing" 519319 Removing and Installing Cover for Centre Underbody
Removing Porsche Double Clutch (PDK)
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 jacking points provided.
-> The outer jacking points should be used primarily.
Information
- When raising the vehicle, take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points.
1. Remove the transverse strut.
Removing and installing cross member
Unscrew screws -2- (M10 x 40) and remove transverse strut -1-.
2. Remove the diagonal braces.
Removing and installing diagonal braces
Unscrew screws -2- (M12 x 30) on the cross member and screws -2- (M10 x 40) on the body and remove diagonal braces -1-.
3. Remove cross member.
Removing and installing cross member
Loosen nuts -1- on the bottom screws (M12 x 80) and unscrew screws; top screws (M12 x 80) only need to be loosened, due to existing slots; remove cross member -2-.
Top mounting for rear cross member
4. Disconnect electric multiple plug connector on the Porsche Double Clutch.
4.1. Turn the bayonet lock on the top electric multiple plug connector -1- to release it and pull it off.
Top Porsche Double Clutch connector
4.2. Turn the bayonet lock on the bottom electric multiple plug connector -1- to release it and pull it off.
Bottom Porsche Double Clutch connector with cable guide
Remove cable for electric multiple plug connector -1- from the cable guide -2-.
4.3. Disconnect cable plug on solenoid valve -1- for disc valve.
Cable plug for solenoid valve for Porsche Double Clutch
5. Remove the speed sender.
Removing and fitting speed sender
Unscrew screw -1- , remove speed sender -2- and place it safely aside.
6. Remove parking lock cable on the Porsche Double Clutch.
Removing parking lock cable
6.1. Press ball head of parking lock cable -1- off the parking lock lever.
6.2. Release parking lock cable -1- at the bracket by pressing the locking lugs -2- together and pull it out.
7. Remove 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. 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 which has been cut open).
8. Support the engine and lower the transmission.
Supporting engine with a unit elevating platform
8.1. Position unit elevating platform under the vehicle, secure retainer plate 9769 ( -2- ) on the unit lifting platform and 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 elevating platform must be positioned slightly diagonally using the adjustment controls so that the bores are directly parallel.
=> Adjustment value: 10°
8.2. Position transmission jack under the ATF pan of the Porsche Double Clutch and secure the PDK using a restraining strap. Make sure that the entire surface of the ATF pan is used as the contact surface so as to avoid damaging the ATF pan.
8.3. Remove gear support.
Removing and installing gear support
Unscrew M10 nuts -2-.
Unscrew M12 screw -3- and remove gear support -1-.
8.4. Lower the transmission.
Only lower the transmission sufficiently to allow access to the screws for the B+ cable duct and coolant pipes.
Information
When lowering and lifting the Porsche Double Clutch, make sure that the sharp cooling fins on the ATF cooler do not damage the left cooling water hose. Move left cooling water hose into position when lowering and lifting the PDK.
9. Remove B+ cable duct.
B+ cable routing on transmission
Remove B+ cable duct -1- by unscrewing the M6 screws -2- and taking out the B+ cable duct -1-.
10. Remove coolant lines and coolant hoses.
10.1. Pull off vacuum line -1- for brake booster.
Brake booster vacuum line
10.2. Close off coolant lines -1- by releasing and pulling off the safety clips on the Henn couplings -arrows-.
Disconnecting and connecting cooling water lines
10.3. Remove cooling water tubes -1- by unscrewing the M6 screws -2-.
Removing and fitting cooling water lines
NOTICE
Mechanical overload of components
- Component will be damaged irreparably
-> Observe guidelines for assembly and disassembly
11. Remove Porsche Double Clutch.
Sequence for loosening Porsche Double Clutch screws
11.1. Loosen and unscrew M12 screws first -1, 2- , then -6, 5, 3- and finally -4-.
Porsche Double Clutch screws
11.2. Lower the Porsche Double Clutch.
Lower the Porsche Double Clutch until it is approx.
=> Control value: 10 mm from the anti-roll bar.
11.3. Remove Porsche Double Clutch by pulling it backwards and drain it.
Installing Porsche Double Clutch (PDK)
Information
When lowering and lifting the Porsche Double Clutch, make sure that the sharp cooling fins on the ATF cooler do not damage the left cooling water hose. Move left cooling water hose into position when lowering and lifting the PDK.
Information
- If the vehicle is placed on its wheels or moved in the workshop, the rear cross member must always be refitted beforehand.
- If the cross member is not refitted, the vehicle will have to be aligned after the engine or transmission is installed.
1. Install Porsche Double Clutch.
Information
After replacing the Porsche Double Clutch (PDK) or after carrying out repairs in the Porsche Double Clutch (PDK), the transmission control unit must be calibrated using PIWIS Tester II 9818.
When replacing the Porsche Double Clutch, please note the following:
Sequence for loosening Porsche Double Clutch screws
NOTICE
Engine housing overload.
- Risk of engine damage if housing breaks.
-> Observe loosening and tightening sequence!
-> Loosening sequence: Loosen screws from the bottom up.
-> Tightening sequence: Tighten screws from top to bottom.
Information
Always replace flange screws.
1.1. Lift up and mount the Porsche Double Clutch.
1.2. Screw in and tighten screws -4- first, then -3, 5, 6- and finally -1, 2-.
Porsche Double Clutch screws
NOTICE
Engine housing overload.
- Risk of engine damage if housing breaks.
-> Observe loosening and tightening sequence!
-> Loosening sequence: Loosen screws from the bottom up.
-> Tightening sequence: Tighten screws from top to bottom.
=> Tightening torque: 85 Nm (63 ftlb.)
2. Fit coolant lines and coolant hoses.
2.1. Connect vacuum line -1- for brake booster.
Brake booster vacuum line
2.2. Connect coolant lines -1- by locking the safety clips on the Henn couplings -arrows-.
Disconnecting and connecting cooling water lines
Information
- The coolant hoses must lock with an audible click when pushed into the plug-in couplings.
2.3. Fit cooling water tubes -1- by screwing in and tightening the M6 screws -2-.
Removing and fitting cooling water lines
=> Tightening torque: 10 Nm (7.5 ftlb.)
3. Fit B+ cable duct.
B+ cable routing on transmission
Fit B+ cable duct -1- by screwing in and tightening the M6 screws -2-.
=> Tightening torque: 10 Nm (7.5 ftlb.)
4. Install gear support and remove unit elevating platform.
4.1. Raise the transmission.
Information
When lowering and lifting the Porsche Double Clutch, make sure that the sharp cooling fins on the ATF cooler do not damage the left cooling water hose. Move left cooling water hose into position when lowering and lifting the PDK.
4.2. Install gear support.
Removing and installing gear support
Fit the gear support -1- and screw on and tighten M10 nuts -2-.
=> Tightening torque: 65 Nm (48 ftlb.)
Screw in and tighten M12 screw -3-.
=> Tightening torque: 120 Nm (89 ftlb.)
4.3. Lower and remove transmission jack -4-.
Supporting engine with a unit elevating platform
4.4. Lower the unit elevating platform -1- , reset it to zero position and remove it.
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
Information
The flanges on the transmission and the drive shaft bolts have been changed to a fine thread from September 2009 onwards. Please read the Technical Information: -> 422100 PDK: Threaded joint between drive shaft and halfshaft flange (fine thread) (20/09)
5.2. Screw in and tighten 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 which has been cut open).
=> Tightening torque: 81 Nm (60 ftlb.)
=> Tightening torque: 90 Nm (67 ftlb.)
6. Engage parking lock cable on the Porsche Double Clutch.
Engaging parking lock cable
6.1. Check that the gear selector on the selector support is in position "P" and is locked.
6.2. Check that the transmission parking lock is fully engaged.
6.3. Fit the parking lock cable -1- on the bracket, press it in and engage it.
6.4. Press ball head of parking lock cable -1- onto the parking lock lever.
Note: The parking lock cable must only be connected without preload.
7. Fit the speed sender.
Removing and fitting speed sender
Fit speed sender -2- and screw in and tighten screw -1-.
=> Tightening torque: 10 Nm (7.5 ftlb.)
8. Connect electric multiple plug connector to the Porsche Double Clutch.
8.1. Connect the bayonet lock on the top electric multiple plug connector -1-.
Top Porsche Double Clutch connector
8.2. Connect the bayonet lock on the bottom electric multiple plug connector -1-.
Bottom Porsche Double Clutch connector with cable guide
8.3. Connect cable plug on solenoid valve -1- for disc valve.
Cable plug for solenoid valve for Porsche Double Clutch
9. Install cross member.
Removing and installing cross member
Position cross member -2- and fit and tighten M12 x 80 screws -1-.
=> Tightening torque: 110 Nm (81.5 ftlb.)
10. Install diagonal braces.
Removing and installing diagonal braces
Fit diagonal braces -1-. Screw in and tighten screws -2- (M12 x 30) on the cross member and screws -2- (M10 x 40) on the body.
=> Tightening torque: 100 Nm (74 ftlb.)
=> Tightening torque: 65 Nm (48 ftlb.)
11. Install the transverse strut.
Removing and installing cross member
Fit transverse strut -1- and screw in and tighten screws -2- (M10 x 40).
=> Tightening torque: 65 Nm (48 ftlb.)
Subsequent work
1. Calibrate the Porsche Double Clutch control unit and erase the fault memory.
PIWIS Tester 9718
2. Check ATF and oil for final drive and top up if necessary.
-> 370235 Checking and topping up ATF
-> 399035 Checking and topping up oil for final drive
3. Adjust the parking lock cable. See Installing parking lock cable. -> 371319 Removing and installing parking lock cable
4. Install underbody panelling.
-> 519319 Removing and installing centre cover - section on "Installing" 519319 Removing and Installing Cover for Centre Underbody-> 519419 Removing and installing rear cover - section on "Installing" 519419 Removing and Installing Cover for Rear Underbody
5. Connect the battery.
-> 2706IN Work instructions after disconnecting the battery