Removing Porsche Doppelkupplung (PDK)

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 support plate.
   1. 1.1. Remove diagonal braces.

      Unscrew M10/M12 screws and M10 nuts and remove diagonal braces -1-  .

   2. 1.2. Remove support plate.

      Unscrew M10 x 25 screws and M10 nuts and remove support plate -2-  .

   Fig 1: Removing Support Plate

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2. Remove cross member.

   Unscrew M10 x 70 screws -1-  and remove cross member -2-  .

   Fig 2: Identifying Cross Member And Screws

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3. Remove parking lock cable on the Porsche Doppelkupplung.
   1. 3.1. Press ball joint of parking lock cable -1-  off the parking lock lever.
   2. 3.2. Release parking lock cable -1-  at the bracket by pressing the locking lugs -arrows-  together and pull it out.
   Fig 3: Removing Parking Lock Cable

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4. Remove drive shafts on the transmission side.
   1. 4.1. Counter using special tool adapter plate 9510/1  (-1-  ).
      Fig 4: Removing Drive Shafts

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   2. 4.2. Unscrew the six bolts between the drive shaft and transmission flange.

      Information 

      • Protect the drive shafts from mechanical damage  .
        Fig 5: Identifying Drive Shaft

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5. Remove anti-roll bar on rear-axle carrier side section.

   Unscrew M8 x 40 screws -1-  and move anti-roll bar -2-  into position.

   Fig 6: Identifying Anti-Roll Bar And Screws

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6. Support the engine and lower the transmission.
   1. 6.1. Retainer plate 9769 -1-  must be secured on the unit lifting platform using an M10 screw.
      Fig 7: Identifying Engine Mounting

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   2. 6.2. Position unit lifting platform -1-  under the vehicle, 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 lifting platform -1-  must be positioned slightly diagonally -3-  using the adjustment controls so that the bores are directly parallel.

      → Adjustment value: 10° 

      Fig 8: Positioning Unit Lifting Platform Under Vehicle

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   3. 6.3. Remove left and right gear support and hydraulic mount.
      1. 6.3.1. Information:  Do not loosen nuts -C-  .

         C  - Nut (never loosen)

         Fig 9: Locating Transmission Support, Hydraulic Mount And Fastening Nuts

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      2. 6.3.2. Unscrew screws -2-  on the transmission supports -3-  .
      3. 6.3.3. Unscrew M8 nuts -1-  between the body and hydraulic mount and remove transmission support with hydraulic mount -3-  .
      Fig 10: Identifying Gear Support And Screws

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   4. 6.4. Lower the transmission.

      Only lower the transmission sufficiently to allow access to the cable connections and coolant hoses.

7. Disconnect electric multiple plug connector on the Porsche Doppelkupplung.
   1. 7.1. Release and pull off the bayonet lock on the electric multiple plug connectors -1-  .
   2. 7.2. Detach clip holders -arrows-  with electric lines -2-  on the transmission and lay electric lines -2-  aside.
   Fig 11: Locating Electric Multiple Plug Connector
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8. Disconnect coolant hoses at the ATF cooler.
   1. 8.1. Clamp coolant hoses.
      Fig 12: Identifying ATF Cooler Coolant Hoses

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   2. 8.2. Disconnect coolant hoses -1-  by releasing the spring band clamps -2-  using a pair of angled spring band pliers -3-  and pull off coolant hoses -1-  .
9. Remove the speed sender.

   Unscrew M6 x 15 screw -1-  , remove speed sender -2-  and place it safely aside.

   Fig 13: Identifying Speed Sender And Screws

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10. Remove holder with solenoid valve for disc valve.
    1. 10.1. Disconnect cable plug -1-  .
    2. 10.2. Unscrew M6 x 12 screw -2-  and position solenoid valve -3-  .
       NOTE: Mechanical overload of components

       • Component will be damaged irreparably

       → Observe guidelines for assembly and disassembly

    Fig 14: Identifying Cable Plug, Position Solenoid Valve And Screws

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11. Remove Porsche Doppelkupplung.
    1. 11.1. Loosen and unscrew M12 x 55 screws first -1, 2-  , then -6, 5, 3-  and finally -4-  .
       Fig 15: Identifying Porsche Doppelkupplung Screws

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    2. 11.2. Lower the Porsche Doppelkupplung.

       Lower the Porsche Doppelkupplung until it is approx.

       → Control value: 10 mm  from the anti-roll bar.

    3. 11.3. Remove Porsche Doppelkupplung by guiding it towards the rear.