Removing Porsche Doppelkupplung (PDK)

→ Secure components to prevent them from falling down.

→ Before lines are opened, place a cloth underneath them!

→ Components that come into contact with ATF must be cleaned IMMEDIATELY with water!

→ Take appropriate protective measures (protective clothing, safety goggles, oil binding material)

→ Collect emerging ATF!

1. Disconnect locking cable on transmission.
   1. 1.1. Press locking cable -1-  off the ball joint -2-  .
   2. 1.2. Unscrew fastening screws -arrows-  and remove support -3-  .

      Locking cable

2. Unscrew fastening screws -3...6-  .

   Mounting point for transmission on engine

   CAUTION: Heavy components

   • Risk of squashing

   → Wear personal protective gear.

   → Get someone to help if necessary.

3. Secure the engine.
   1. 3.1. Position dome strut -1-  and tighten screws hand-tight.
   2. 3.2. Secure tension strap -2-  at the engine suspension eyelet and dome strut.
   3. 3.3. Secure the engine with a tension strap.

      Securing engine (illustration shows V6 Diesel)

4. Remove heat shields on right drive shaft.

   Unscrew fastening screws -arrows-  and remove heat shields.

   Heat shield for drive shaft

5. Unscrew fastening screws -1 and 2-  and remove heat shields at the left and right.

   Heat shield on front-axle carrier

   NOTE:

   • Disconnect universal joint from the steering gear only when the front wheels are in straight-ahead position. 
   • To ensure that the position of the steering wheel and steering gear cannot change, secure the steering wheel. (Engage steering column lock or clamp the steering wheel in center position with a steering-wheel holder.) 
6. Unscrew fastening screw -arrow-  and pull universal joint off the steering gear.

   Universal joint

7. Unscrew fastening screw -arrow-  and pull ATF line -1 and 2-  out of the ATF spin-on filter housing.
   1. 7.1. Collect emerging oil.
   2. 7.2. Close off connections and openings using suitable stoppers.

      ATF line on ATF spin-on filter housing

8. Disconnect wiring harness at the transmission.
   1. 8.1. Release and disconnect electric connector -1 and 2-  .
   2. 8.2. Loosen holder -arrows-  for wiring harness and expose it.

      Engine wire harness on transmission

9. Pull off cover -1-  on the underside of the transmission.

   Cover on drive plate

10. Loosen dual-mass flywheel from the drive plate.
    1. 10.1. Counter the crankshaft using adapter T40058  .
    2. 10.2. Loosen fastening screws -arrow-  .
    3. 10.3. For the next screw, use adapter T40058  to turn the crankshaft a further 60° in direction of rotation of engine  .

       Dual-mass flywheel

11. Unscrew fastening screws -8 and 9-  .

    Mounting point for transmission on engine

12. Gearbox support T40173  must be prepared for use.
    1. 12.1. Remove mounting block -1-  .
    2. 12.2. Fit mounting block -2-  upright.

       Gearbox support T40173

    NOTE: Engine/transmission is supported on the oil pan.

    • Leaks at the oil pan

    → Use prescribed tools and aids.

13. Engine and gearbox jack WE 1599  must now be fitted on the transmission using the prepared gearbox support T40173  .
    1. 13.1. The mounting block -2-  engages in the opening on the dual-mass flywheel.
    2. 13.2. Fit right mounting with elastic intermediate layer -1-  on the center differential.
    3. 13.3. Secure the transmission with a tension strap.

       Fitting transmission jack T40173 on transmission

14. Unscrew fastening screws -1 and 3-  on the transmission support -2-  .

    Gear support

15. Unscrew fastening screws -1, 2, 7 and 10-  .

    Tool recommendation for fastening screw -1-: 3/4" flexible-head socket a/f 16. 

    Mounting point for transmission on engine

    NOTE:

    • Get a second person to help to remove and install the transmission and ensure adequate clearance. 
16. Separate transmission from engine.