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 

• The aluminum screws for the differential housing cover must be replaced. 
• The aluminum screws for the Porsche Doppelkupplung (PDK) must be tightened using the yield-point-controlled tightening method. 
• Special tool electronic torque wrench 9768 is used for this. 
• To ensure that the screws are tightened uniformly, the corresponding tightening setting "light, medium or hard" must always be used. 

1. Install Porsche Doppelkupplung.

   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  .

   When replacing the Porsche Doppelkupplung, please note the following:

   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.

   Information 

   Replace flange screws if necessary.

   1. 1.1. Lift up and mount the Porsche Doppelkupplung.
   2. 1.2. 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

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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 holder with solenoid valve for disc valve.
   1. 2.1. Fit solenoid valve -3-  and screw in and tighten M6 x 12 screw -2-  .

      → Tightening torque: 10 Nm (7.5 ftlb.) 

   2. 2.2. Connect cable plug -1-  .
   Fig 2: Identifying Cable Plug, Solenoid Valve And Screws

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3. Fit the speed sender.

   Fit speed sender -2-  and screw in and tighten M6 x 15 screw -1-  .

   → Tightening torque: 10 Nm (7.5 ftlb.) 

   Fig 3: Identifying Speed Sender And Screw

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4. Connect coolant hoses at the ATF cooler.
   1. 4.1. Connect coolant hoses -1-  by releasing the spring band clamps -2-  using a pair of angled spring band pliers -3-  and securing them on the coolant hoses -1-  .
      Fig 4: Identifying ATF Cooler Coolant Hoses

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   2. 4.2. Remove hose clamps.
5. Connect electric multiple plug connector to the Porsche Doppelkupplung.
   1. 5.1. Release and pull off the bayonet lock on the electric multiple plug connectors -1-  .
   2. 5.2. Route electric lines -2-  and secure on the transmission -arrows-  .
   Fig 5: Locating Electric Multiple Plug Connector

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6. Install gear support.
   1. 6.1. Raise the transmission.

      Hydraulic garage jack H 2 SL WE 1032 

   2. 6.2. 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.) 

      Fig 6: Identifying Gear Support

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   3. 6.3. Lower and remove transmission jack.
      Fig 7: Removing Transmission Jack

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   4. 6.4. Lower the unit lifting platform -1-  , reset it to zero position and remove it.
   5. 6.5. Retainer plate 9769  (-1-  ) must be removed from the unit lifting platform.
   Fig 8: Identifying Engine Mounting

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7. 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 9: Identifying Anti-Roll Bar

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8. Fit drive shafts on the transmission side.
   1. 8.1. Counter using special tool adapter plate 9510/1  (-1-  ).
      Fig 10: Fitting Drive-Shaft

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   2. 8.2. Screw in and tighten the six M10 bolts between the drive shaft and transmission flange.

      → Tightening torque: 81 Nm (60 ftlb.) 

      Fig 11: Identifying Drive Shaft

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9. Engage parking lock cable on the Porsche Doppelkupplung.
   1. 9.1. Check that the gear selector on the selector support is in position "P" and is locked.
   2. 9.2. Check that the transmission parking lock is fully engaged.
   3. 9.3. Fit the parking lock cable -arrow-  on the bracket, press it in and engage it.
   4. 9.4. Press ball joint of parking lock cable -1-  onto the parking lock lever.
      NOTE: The parking lock cable must only be connected without preload.
   Fig 12: Engaging Parking Lock Cable

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10. 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 13: Identifying Transverse Strut Cross Member And Screw

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11. Install support plate.
    1. 11.1. 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. 11.2. 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 14: Installing Support Plate

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