Installing Transmission

Information 

Before installing the transmission, clean splines of transmission input shaft and grease lightly, e.g. with Olista Longtime 3 EP.

→ Observe guidelines for assembly and disassembly

1. Install transmission.
   1. 1.1. Screw in and tighten screws -4-  first, then -3, 5, 6-  and finally -1, 2-  .

      → Tightening torque: 85 Nm (63 ftlb.) 

      Fig 1: Identifying Porsche Doppelkupplung Screws Loosening/Tightening Sequence

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2. Install clutch slave cylinder.
   1. 2.1. Guide the clutch slave cylinder into the opening on the transmission and screw in M8 screw.

      → Tightening torque: 23 Nm (17 ftlb.) 

      Fig 2: Identifying Clutch Slave Cylinder Screw

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      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. 2.2. Fit external shift mechanism and screw on M8 nut.

      → Tightening torque: 23 Nm (17 ftlb.) 

      Fig 3: Locating External Shift Mechanism Fastening Nut

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3. Install transmission holder.
   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-  .

      → Tightening torque: 65 Nm (48 ftlb.) 

      → Tightening torque: 23 Nm (17 ftlb.) 

      Fig 4: Identifying Gear Support Screw

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   3. 3.3. Lower and remove transmission jack.
      Fig 5: Lifting Engine Platform

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   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 6: Identifying Engine Mounting

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4. Fit anti-roll bar on rear-axle carrier side section.

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

   → Tightening torque: 23 Nm (17 ftlb.) 

   Fig 7: Locating Anti-Roll Bar

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5. Fit drive shafts on the transmission side.
   1. 5.1. Counter using special tool adapter plate 9510/1  (-1-  ).
      Fig 8: Identifying Drive-Shaft Bolts Retaining Tool

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   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 9: Identifying Drive Shaft

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6. Install the transverse strut.

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

   → Tightening torque: 65 Nm (48 ftlb.) 

   Fig 10: Locating Cross Member

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7. Connect 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.

   Fig 11: Engaging Shift And Selector Cables

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8. Connect cable plug for reversing light switch.
   Fig 12: Locating Reversing Light Switch

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9. Install support plate.
   1. 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.) 

   2. 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.) 

   Fig 13: Installing Support Plate

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