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Home >> Porsche >> 2008 >> Boxster S, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (37 - Automatic Transmission - Actuation, Ass. Housing -- 987-BOXSTER-CAYMAN) >> WM 375019 Removing And Installing Assembly Cover (All Models) >> Installing Assembly Cover

Installing Assembly Cover

WARNING: This page is about a different variant/trim than selected.
  1. Drive in assembly cover.
    1. 1.1. Coat assembly cover lightly with fresh transmission oil.
    2. 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.
      NOTE: 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.

      Fig 1: Installing Assembly Cover
      G09587000Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Install exhaust system suspension.

    Fit suspension and screw in and tighten M8 screws.

    → Tightening torque: 45 Nm (33 ftlb.) 

    Fig 2: Identifying Exhaust System Suspension
    G09587001Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Install gear support.
    1. 3.1. Raise the transmission.

      Hydraulic garage jack H 2 SL WE 1032 

    2. 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.) 

      Fig 3: Identifying Gear Support And Screws
      G09587002Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 3.3. Lower and remove transmission jack.
      Fig 4: Removing Transmission Jack
      G09587003Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 3.4. Lower the unit lifting platform -1-  , reset it to zero position and remove it.
    5. 3.5. Retainer plate 9769  (-1-  ) must be removed from the unit lifting platform.
    Fig 5: Identifying Engine Mounting
    G09587004Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Fit anti-roll bar on rear-axle carrier side section.

    Move anti-roll bar -2-  into position and screw in and tighten M8 x 40 screws -1-  .

    → Tightening torque: 23 Nm (17 ftlb.) 

    Fig 6: Identifying Anti-Roll Bar And Screws
    G09587005Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Fit drive shafts on the transmission side.
    1. 5.1. Counter using special tool adapter plate 9510/1  (-1-  ).
      Fig 7: Installing Drive-Shaft
      G09587006Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 5.2. Screw in and tighten the six M10 bolts between the drive shaft and transmission flange.

      → Tightening torque: 81 Nm (60 ftlb.) 

      Fig 8: Identifying Drive Shaft
      G09587007Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Install the transverse strut.

    Fit cross member -2-  and screw in and tighten M10 x 72 screws -1-  .

    → Tightening torque: 65 Nm (48 ftlb.) 

    Fig 9: Identifying Transverse Strut And Screws
    G09587008Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Engage parking lock cable on the Porsche Doppelkupplung.
    1. 7.1. Check that the gear selector on the selector support is in position "P" and is locked.
    2. 7.2. Check that the transmission parking lock is fully engaged.
    3. 7.3. Fit the parking lock cable -arrow-  on the bracket, press it in and engage it.
    4. 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.
    5. Fig 10: Engaging Parking Lock Cable
      G09587009Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Install support plate.
    1. 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.) 

    2. 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.) 

    Fig 11: Installing Support Plate
    G09587010Courtesy of PORSCHE CARS NORTH AMERICA, INC.