Installing Transfer Box

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

Support main transmission on converter bell housing with a wooden block -arrow- .

Fig 1: Supporting Transmission Using Wooden Block
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Gradually run in transfer box. Press vent line into holder -arrow- and attach to transfer box.

Fig 2: Locating Vent Line Retainers
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Tighten fastening screws on main transmission. → Tightening torque: 45 Nm (33 ft lbs.)

Fig 3: Locating Transfer Box To Main Transmission Fastening Screws
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Tighten support -A- for Tiptronic line using fastening nut -arrow- . → Tightening torque: 10 Nm (7.5 ft lbs.)

Fig 4: Locating Tiptronic Line Fastening Nut
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Support transfer box with transmission jack and remove wooden block between converter bell housing and suspension sub-frame.

Fig 5: Supporting Transmission Using Wooden Block
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Information

Always observe the exact work sequence when installing/removing the transmission cross member.

Information
- Screws which are tightened with a torque angle must be replaced with new ones.
Install transmission cross member.
Screw in two cross member screws -B- on transfer box support. → Initial tightening: 50 Nm (37 ft lbs.) → Final tightening: 90° (67 ft lbs.)

Fig 6: Identifying Transmission Cross Member Screws
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Screw in fastening screws for securing transmission cross member to body -A- . → Initial tightening: 50 Nm (37 ft lbs.) → Final tightening: 90° (67 ft lbs.)
Information
- Screws which are tightened with a torque angle must be replaced with new ones.
Connect front cardan shaft to transfer box. → Initial tightening: 30 Nm (22 ft lbs.) → Final tightening: 90° (67 ft lbs.)

Fig 7: Identifying Front Cardan Shaft To Transfer Box Fastening Screws
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Information
- The temperature sensor -1- on the transfer box is no longer used in model year 2004.
- If there is no temperature sensor, secure cable plug on the servo motor with tiewraps.
  
  Fig 8: Identifying Transfer Box Servo Motor Plug Sequence
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Connect cable plug -1, 2- to the transfer box and secure the cable holder.

Fig 9: Identifying Servo Motor Cable Plug
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Fit heat protection to the cable plugs on the servo motor.

Fig 10: Identifying Heat Protection Cover On Servo Motor
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