Installing Porsche Doppelkupplung (PDK)

Information 

• If the vehicle is placed on its wheels or moved in the workshop, the rear cross member must always be refitted beforehand. 
• Without fitting the rear-axle cross member, the vehicle's suspension must be aligned after installing the engine or transmission. 

Information 

After replacing the Porsche Doppelkupplung (PDK) or after carrying out repairs in the Porsche Doppelkupplung (PDK), the transmission control unit must be calibrated using PIWIS Tester II 9818  .

1. Install Porsche Doppelkupplung.
   Fig 1: Installing Porsche Doppelkupplung

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   NOTE: 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.

   1. 1.1. Lift up and mount the Porsche Doppelkupplung.
   2. 1.2. Screw in and tighten screw -4-  first, then -3, 5, 6-  and finally -1, 2-  .

      → Tightening torque: 85 Nm (63 ft. lb.) 

      Fig 2: Identifying Porsche Doppelkupplung Screws

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      NOTE: 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.

2. Fit coolant lines and coolant hoses.
   1. 2.1. Connect vacuum line -1-  for brake booster.
      Fig 3: Identifying Brake Booster Vacuum Line

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   2. 2.2. Connect and secure coolant lines on the transmission side -arrows-  .
      Fig 4: Loosening/Securing Coolant Lines

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   3. 2.3. Fit cooling water tubes -1-  by screwing in and tightening the M6 screws -2-  .

      → Tightening torque: 10 Nm (7.5 ft. lb.) 

      Fig 5: Identifying Cooling Water Lines

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3. Fit B+ cable duct.

   Fit B+ cable duct -1-  by screwing in and tightening the M6 screws -2-  .

   → Tightening torque: 10 Nm (7.5 ft. lb.) 

   Fig 6: Identifying B+ Cable Routing On Transmission

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4. Install gear support and remove unit elevating platform.
   1. 4.1. Raise the transmission.

      Information 

      When lowering and lifting the Porsche Doppelkupplung, 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.

   2. 4.2. Install gear support.

      Fit the gear support -1-  and screw on and tighten M10 nuts -2-  .

      → Tightening torque: 65 Nm (48 ft. lb.) 

      Insert and tighten M12 screw -3-  .

      → Tightening torque: 120 Nm (89 ft. lb.) 

      Fig 7: Identifying Gear Support

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   3. 4.3. Lower and remove transmission jack -4-  .
      Fig 8: Supporting Engine Using Unit Elevating Platform

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   4. 4.4. Lower the unit lifting platform -1-  , reset it to zero position and remove it.

      Information 

      The flanges on the transmission and the drive shaft bolts have been changed to a fine thread from September 2009 onwards.

5. Fit drive shafts on the transmission side. To do this, screw in and tighten six screws on each. → 4201TW TIGHTENING TORQUES FOR REAR AXLE
   Fig 9: Fitting Drive Shafts On Transmission Side

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6. Engage parking lock cable on the Porsche Doppelkupplung.
   Fig 10: Engaging Parking Lock Cable

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   1. 6.1. Check that the gear selector on the selector support is in position "P" and is locked.
   2. 6.2. Check that the transmission parking lock is fully engaged.
   3. 6.3. Fit the parking lock cable -1-  on the bracket, press it in and engage it.
   4. 6.4. Press ball joint of parking lock cable -1-  onto the parking lock lever.
      NOTE: The parking lock cable must only be connected without preload.
7. Fit the speed sender.

   Fit speed sender -2-  and screw in and tighten screw -1-  .

   → Tightening torque: 10 Nm (7.5 ft. lb.) 

   Fig 11: Identifying Speed Sender

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8. Connect electric multiple plug connector to the Porsche Doppelkupplung.
   1. 8.1. Connect the bayonet lock on the top electric multiple plug connector -1-  .
      Fig 12: Connecting Top Porsche Doppelkupplung Connector

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   2. 8.2. Connect the bayonet lock on the bottom electric multiple plug connector -1-  .
      Fig 13: Identifying Bottom Porsche Doppelkupplung Connector With Cable Guide

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   3. 8.3. Connect cable plug on solenoid valve -1-  for disc valve.
      Fig 14: Identifying Cable Plug For Solenoid Valve For Porsche Doppelkupplung

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9. Install cross member.

   Position cross member -2-  and fit and tighten screws -1-  . → 4201TW TIGHTENING TORQUES FOR REAR AXLE

   Fig 15: Identifying Cross Member

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10. Install diagonal braces.

    Fit diagonal braces -1-  . Screw in and tighten screws -2-  on the cross member and screws -2-  on the body. → 4201TW TIGHTENING TORQUES FOR REAR AXLE

    Fig 16: Identifying Diagonal Braces

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11. Install the transverse strut.

    Fit transverse strut -1-  and screw in and tighten screws -2-  (M10 x 40). → 4201TW TIGHTENING TORQUES FOR REAR AXLE

    Fig 17: Identifying Transverse Strut

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