Installing Front-Axle Cross Member

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2019 Porsche 911, 2018 Porsche 911, 2017 Porsche 911, 2016 Porsche 911, and 2015 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.

Check the bellows and clamping rings for damage and make sure they are seated securely. Replace them if necessary.
Lift the front-axle carrier using a transmission jack.
Plug in battery connector -2- and vehicle signal connector -3- on the steering gear motor until they engage securely. The torque sensor connector -1- (connector at the very top) was not disconnected when the front-axle carrier was removed.

Fig 1: Identifying Steering Gear Control Unit Connectors
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install front-axle cross member.

Fig 2: Locating Front-Axle Cross Member Mounting
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 4.1. Carefully move the front-axle cross member -2- into installation position using the hydraulic lift.
  Make sure not to trap any lines and plug connections.
  
  Check that the lines are routed correctly.
2. 4.2. Screw in and tighten new fastening screws -5- for the front-axle cross member to the specified tightening torque.
  When fitting the front-axle cross member, always fit the screws straight because if they are fitted crooked, the thread of the body can become damaged when tightening the screws.
  
  Fastening screws (M12 x 1.5 x 50) for front-axle cross member, inner front. → Tightening torque: 90 Nm (67 ftlb.)+90°
  
  Fastening screws (M12 x 1.5 x 105) for front-axle cross member, outer front. → Tightening torque: 90 Nm (67 ftlb.)+180°
3. 4.3. Tighten new fastening nuts (M12 x 1.5) on the front-axle cross member -6- to the specified tightening torque and counter at the bolt using a Torx wrench (T40).
  Fastening nut on front-axle cross member, centre front. → Tightening torque: 90 Nm (67 ftlb.)+90°
4. 4.4. Clip in clips for coolant pipes -4- and screw in and tighten fastening screws (M6 x 20) -3- to the specified tightening torque.
  → Tightening torque: 10 Nm (7.5 ftlb.)
5. 4.5. Move the two longitudinal struts -1- (at the left and right) into installation position.
6. 4.6. Screw in and tighten the new fastening screws (M12 x 1.5 x 58) to the specified tightening torque.
  Fastening screws securing front-axle cross member and longitudinal strut to body. → Tightening torque: 90 Nm (67 ftlb.)+ 90°
7. 4.7. Tighten the M10 fastening nuts to the specified tightening torque.
  Fastening nut securing longitudinal strut to body. → Tightening torque: 65 Nm (48 ftlb.)
Also for all-wheel drive vehicles: Fit bracket -1- on the front-axle cross member.
1. 5.1. Screw in and tighten studs -3- .
  → Tightening torque: 17 Nm (13 ftlb.)
2. 5.2. Screw hexagon nuts -2- on studs -3- and tighten them.
  → Tightening torque: 65 Nm (48 ftlb.)
  
  Fig 3: Identifying Front Final Drive Bracket
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Secure universal joint to the steering gear.

Fig 4: Identifying Steering Column Universal Joint
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1. 6.1. Connect universal joint to the steering gear.
2. 6.2. Fit new fastening screw -1- in the universal joint and tighten to the specified tightening torque.
  Fastening screw (M8 x 30) securing universal joint at the bottom to steering gear. → Tightening torque: 20 Nm (15 ftlb.)+90°
Secure connecting links to anti-roll bar.

Fig 5: Identifying Lower Connecting Link Mounting
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 7.1. Guide ball-joint pin into the bore in the anti-roll bar.
2. 7.2. Tighten new fastening nut -1- to the specified tightening torque. To tighten the fastening nut, counter with screwdriver 9546 (Torx screwdriver) at the ball-joint pin.
  On vehicles without PDCC (Porsche Dynamic Chassis Control): Fastening nut securing connecting link to anti-roll bar. → Tightening torque: 40 Nm (30 ftlb.)+30°
  
  On vehicles with PDCC (Porsche Dynamic Chassis Control): Fastening nut securing PDCC actuator to anti-roll bar. → Tightening torque: 50 Nm (37 ftlb.)+50°
Secure lower front-axle wishbone at the outside.

Fig 6: Securing Lower Front-Axle Wishbone
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1. 8.1. Insert ball joint of the outer front-axle wishbone into the wheel carrier.
2. 8.2. Tighten fastening nut (M12 x 1.5) -1- to the specified tightening torque.
  → Tightening torque: 85 Nm (63 ftlb.)
3. 8.3. Remove cable straps.
Secure tie rod to the left wheel carrier.

Fig 7: Securing Tie Rod To Wheel Carrier
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1. 9.1. Guide in control arm spoiler (air guide for brake cooling) and clip it in at the back of the longitudinal arm.
2. 9.2. Tighten fastening nut (M12 x 1.5) -1- to the specified tightening torque. Counter with screwdriver 9546 (Torx screwdriver) at the ball-joint pin while doing this.
  → Tightening torque: 85 Nm (63 ftlb.)
Clip in ball joint for the linkage rod -1- of the left height sensor on the trailing arm.

Fig 8: Locating Height Sensor Ball Joint
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Secure bracket for height sensor and left coolant pipe.

Fig 9: Identifying Height Sensor Mounting
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1. 11.1. Move bracket for height sensor and left coolant pipe into installation position.
2. 11.2. Screw in and tighten hexagon-head bolt (M6 x 45) -1- to the specified tightening torque.
  → Tightening torque: 10 Nm (7.5 ftlb.)
Repeat Steps 7 - 11 on the right side.
Information
- Some of the repair illustrations show only one side of the vehicle.
- Naturally, some steps also have to be performed on the opposite side of the vehicle as well.
Install sub-frame (front-axle support).

Fig 10: Identifying Sub-Frame (Front-Axle Support)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 13.1. Fit tray for fuel tank.
2. 13.2. Engage retaining straps for the fuel tank and swivel the sub-frame (front-axle support) -1- up.
3. 13.3. Tighten M10 fastening nuts/fastening screws -2- to the specified tightening torque.
  → Tightening torque: 65 Nm (48 ftlb.)
4. 13.4. Screw in and tighten both hexagon-head bolts (M6 x 15) -3- for the centre coolant pipes to the specified tightening torque.
  → Tightening torque: 10 Nm (7.5 ftlb.)