Removing Porsche Doppelkupplung (PDK)

DANGER 

Vehicle can fall down 

• Risk of squashing or crushing 
• Risk of damage to the vehicle 

→ Do not place any solid objects under the raised vehicle.

→ Ensure that the lifting platform is prevented from lowering.

→ Remove solid objects before lowering the vehicle.

→ Raise the vehicle only at the jacking points provided.

→ The outer jacking points should be used primarily.

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 transverse strut.

   Unscrew screws -2-  (M10 x 40) and remove transverse strut -1-  .

   Fig 1: Removing And Installing Transverse Strut

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2. Remove diagonal braces.

   Unscrew screws -2-  (M12 x 30) on the cross member and screws -2-  (M10 x 40) on the body and remove diagonal braces -1-  .

   Fig 2: Removing And Installing Diagonal Braces

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3. Remove cross member.
   Fig 3: Removing And Installing Cross Member

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   Loosen nuts -1-  on the bottom screws (M12 x 80) and unscrew screws; top screws (M12 x 80) only need to be loosened, due to existing slots; remove cross member -2-  .

   Fig 4: Locating Top Mounting For Rear Cross Member

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4. Disconnect electric multiple plug connector on the Porsche Doppelkupplung (PDK).
   1. 4.1. Turn the bayonet lock on the top electric multiple plug connector -1-  to release it and pull it off.
      Fig 5: Turning Bayonet Lock On Top Electric Multiple Plug Connector

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   2. 4.2. Turn the bayonet lock on the bottom electric multiple plug connector -1-  to release it and pull it off.

      Remove cable for electric multiple plug connector -1-  from the cable guide -2-  .

      Fig 6: Identifying Bottom Porsche Doppelkupplung (PDK) Connector With Cable Guide

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   3. 4.3. Disconnect cable plug on solenoid valve -1-  for disc valve.
      Fig 7: Identifying Cable Plug For Solenoid Valve For Porsche Doppelkupplung (PDK)

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5. Remove the speed sender.

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

   Fig 8: Removing And Fitting Speed Sender

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6. Remove parking lock cable on the Porsche Doppelkupplung (PDK).
   Fig 9: Removing Parking Lock Cable

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   1. 6.1. Press ball joint of parking lock cable -1-  off the parking lock lever.
   2. 6.2. Release parking lock cable -1-  at the bracket by pressing the locking lugs -2-  together and pull it out.

      Information 

      • Protect the drive shafts from mechanical damage. 
7. Remove drive shafts at the transmission side. To do this, unscrew six screws on each.
   Fig 10: Identifying Drive Shaft

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8. Support the engine and lower the transmission.
   Fig 11: Supporting Engine With Unit Elevating Platform

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   1. 8.1. Position unit lifting platform under the vehicle, secure retainer plate 9769 (-2-)  on the unit lifting platform and 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 must be positioned slightly diagonally using the adjustment controls so that the bores are directly parallel.

      → Adjustment value: 10° 

   2. 8.2. Position transmission jack under the ATF pan of the Porsche Doppelkupplung (PDK) and secure the PDK using a restraining strap. Make sure that the entire surface of the ATF pan is used as the contact surface so as to avoid damaging the ATF pan  .
   3. 8.3. Remove gear support.

      Unscrew M10 nuts -2-  .

      Unscrew M12 screw -3-  and remove gear support -1-  .

      Fig 12: Removing And Installing Gear Support

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   4. 8.4. Lower the transmission.

      Only lower the transmission sufficiently to allow access to the screws for the B+ cable duct and coolant pipes.

      Information 

      When lowering and lifting the Porsche Doppelkupplung, make sure that the sharp cooling fins on the ATF cooler do not damage the left cooling water hose. Move left cooling water hose into position when lowering and lifting the PDK.

9. Remove B+ cable duct.

   Remove B+ cable duct -1-  by unscrewing the M6 screws -2-  and taking out the B+ cable duct -1-  .

   Fig 13: Identifying B+ Cable Routing On Transmission

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10. Remove coolant lines and coolant pipes.
    1. 10.1. Pull off vacuum line -1-  for brake booster.
       Fig 14: Identifying Brake Booster Vacuum Line

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    2. 10.2. Press off coolant lines and remove them on the transmission side -arrows-  .
       Fig 15: Loosening/Securing Coolant Lines

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    3. 10.3. Remove cooling water tubes -1-  by unscrewing the M6 screws -2-  .
       Fig 16: Identifying Cooling Water Lines

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       NOTE: Mechanical overload of components

       • Component will be damaged irreparably

       → Observe guidelines for assembly and disassembly

11. Remove Porsche Doppelkupplung (PDK).
    Fig 17: Removing Porsche Doppelkupplung (PDK)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 11.1. Loosen and unscrew M12 screws -1, 2-  first, then -6, 5, 3-  and finally -4-  .
       Fig 18: Identifying Porsche Doppelkupplung (PDK) Screws

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    2. 11.2. Lower the Porsche Doppelkupplung (PDK).

       Lower the Porsche Doppelkupplung (PDK) until it is approx.

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

    3. 11.3. Remove Porsche Doppelkupplung (PDK) by pulling it backwards and drain it.