Removing Front-Axle Cross Member

→ Let hot components cool down.

→ Wear personal protective gear.

Fig 1: Identifying Front-Axle Cross Member Installation Position

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Remove sub-frame (front-axle support).
   Fig 2: Identifying Sub-Frame Mounting (Front-Axle Support)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 1.1. Unscrew both hexagon-head bolts (M6 x 15) -3-  for the centre coolant pipes.
   2. 1.2. Unscrew M10 fastening nuts/fastening screws -2-  .
   3. 1.3. Swivel the sub-frame (front-axle support) -1-  down and disengage the retaining straps for the fuel tank.
   4. 1.4. Remove tray for fuel tank in a downward direction.
2. Disconnect universal joint on steering gear.
   Fig 3: Locating Steering Column Universal Joint

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 2.1. Unscrew and remove fastening screw (M8 x 30) -1-  on the universal joint.

      Make sure that the steering wheel is in centre position.

      Replace fastening screw 

3. Loosen connecting links on the anti-roll bar.
   Fig 4: Identifying Lower Connecting Link Mounting

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 3.1. Unscrew fastening nut (M10 x 1.5 and M12 x 1.2) -1-  . To unscrew the fastening nut, counter with screwdriver 9546  (Torx screwdriver) at the ball-joint pin.

      Replace fastening nut 

   2. 3.2. Remove ball-joint pin from the bore in the anti-roll bar.
4. Loosen connecting links on the left wheel carrier. To loosen the lock nut (M12 x 1.5), counter with screwdriver 9546  (Torx screwdriver) at the ball-joint pin.
   Fig 5: Pressing Ball Joint On Tie Rod

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 4.1. Then press off tie-rod ball joint using press-out tool 9560 -1-  . Coat the bellows and press-out tool in this area with tyre mounting paste to prevent damage to the bellows on the ball joint.

      Unclip and remove control arm spoiler -2-  (air guide for brake cooling) on the back of the longitudinal arm.

5. Loosen lower front-axle wishbone at the outside.
   Fig 6: Loosening Lower Front-Axle Wishbone On Wheel Carrier

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 5.1. Secure the spring strut and wheel carrier to the body using a cable strap -1-  to avoid putting extra pressure on the spring-strut mount.

      To do this, pull the cable strap through behind the clamping screw (shock-absorber pipe clamp) -3-  on the spring strut and secure it to the rear opening on the spring-strut mount -2-  .

   2. 5.2. Unscrew fastening nut on the ball joint of the wishbone -5-  and press off the ball joint using press-out tool 9560 -4-  .

      Coat the bellows and press-out tool in this area with tyre mounting paste to prevent damage to the bellows on the ball joint.

6. Disconnect ball joint on the linkage rod -1-  of the left height sensor from the trailing arm.
   Fig 7: Locating Height Sensor Ball Joint

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Disconnect mounting for height sensor and left coolant pipe.
   Fig 8: Identifying Height Sensor Mounting

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 7.1. Unscrew hexagon-head bolt (M6 x 45) -1-  .
8. Repeat Steps  3 -  7 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. 
9. Also for all-wheel drive vehicles: 

   Support the front final drive using a suitable transmission jack. Loosen bracket -1-  for front final drive on the front-axle cross member.

   Fig 9: Identifying Front Final Drive Bracket

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 9.1. Unscrew and remove hexagon nuts -2-  .

      Unscrew and remove studs -3-  .

10. Remove front-axle cross member.
    Fig 10: Locating Front-Axle Cross Member Mounting

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 10.1. Support the front-axle cross member -2-  with a hydraulic lift (use a hard rubber base or wooden block).
    2. 10.2. Remove the two longitudinal struts -1-  (at the left and right) by unscrewing the nuts and threaded connections.

       Replace fastening screws 

    3. 10.3. Unscrew fastening screws (M6 x 20) -3-  and loosen clips -4-  on the bracket for the coolant pipes.
    4. 10.4. Unscrew fastening nuts (M12 x 1.5) -6-  on the front-axle cross member and counter at the bolt using a Torx wrench (T40).

       Replace fastening nuts 

    5. 10.5. Unscrew inner fastening screws (M12 x 1.5 x 50) and outer fastening screws (M12 x 1.5 x 105) -5-  .
    6. 10.6. Lower the front-axle cross member as far as required until you have enough room to disconnect the plug connections for the steering gear.
11. Release and unplug battery connector -2-  and vehicle signal connector -3-  from the steering gear motor. The torque sensor connector -1-  (connector at the very top) remains connected.
    Fig 11: Identifying Steering Gear Control Unit Connectors

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
12. Remove front-axle carrier. To do this, lower the front-axle cross member using a hydraulic lift.