Removing Porsche Doppelkupplung (PDK)

→ 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 diagonal braces.
   1. 1.1. Unscrew screws -1-  on the mounting for the longitudinal arm.
   2. 1.2. Unscrew screws -2-  on the body.
   3. 1.3. Unscrew screws -3-  on the cross member.
   4. 1.4. Remove diagonal braces -A-  .
      Fig 1: Removing Diagonal Braces

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      WARNING: Caustic fluids

      • Danger of chemical burns

      → Avoid contact with caustic fluid.

      → Wear personal protective gear.

      → Ensure that there is good ventilation.

      → If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

2. Only for vehicles with PDCC: 

   Remove PDCC lines.

   1. 2.1. Position container for collecting Pentosin.
   2. 2.2. Unscrew union nuts -1-  .
      Fig 2: Identifying Threaded Joint For PDCC Lines

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   3. 2.3. Unclip PDCC lines -A-  from the brackets -1-  .
      Fig 3: Identifying Bracket For PDCC Lines

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   4. 2.4. Remove bracket for PDCC lines.
      Fig 4: Identifying Bracket For PDCC Lines

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      1. 2.4.1. Unscrew screws -1-  .
      2. 2.4.2. Remove bracket -A -  .
   5. 2.5. Leave PDCC lines hanging in a safe place.
3. Disconnect cable plug on the temperature sensor.
   1. 3.1. Disconnect cable plug -A-  .
   2. 3.2. Unclip cable holder -1-  .
   3. 3.3. Pull off cable holder -2-  .
      Fig 5: Disconnecting Cable Plug

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      Information 

      • Protect the drive shafts from mechanical damage. 
4. Remove drive shafts on the transmission side.
   1. 4.1. Unscrew screws -arrows-  between the drive shaft and transmission flange.

      Counter at the wheel to prevent it from turning as well. Get another person to help if necessary.

   2. 4.2. Remove screws together with the plates -1-  .
   3. 4.3. Suspend the drive shaft with a tie-wrap in a safe place.
      Fig 6: Locating Drive Shafts Screws

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5. Loosen rear-axle cross member.

   → 420609 LOOSENING AND SECURING REAR-AXLE CROSS MEMBER .

6. Disconnect parking lock cable on the Porsche Doppelkupplung (PDK).
   1. 6.1. Press the ball joint off the parking lock lever using disassembly tool Nr.21  .
   2. 6.2. Release the locking cable -1-  on the support -2-  and pull it out.
      Fig 7: Disconnecting Lock Cable On Transmission

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7. Disconnect electric connectors on the Porsche Doppelkupplung (PDK).
   1. 7.1. Turn the bayonet lock on the top multiple plug connector -1-  to release it and pull it off.
      Fig 8: Turning Bayonet Lock On Multiple Plug Connector (Top Multiple)

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   2. 7.2. Disconnect top solenoid valve cable plug -2-  .
   3. 7.3. Turn the bayonet lock on the bottom multiple plug connector -1-  to release it and pull it off.
      Fig 9: Turning Bayonet Lock On Multiple Plug Connector (Bottom Multiple)

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   4. 7.4. Disconnect bottom solenoid valve cable plug -2-  .
8. Detach part of cover for centre underbody.
   1. 8.1. Unscrew the four rear screws on the underbody panelling.

      Information 

      • Do not kink underbody panelling. 
9. Remove brace plate.
   1. 9.1. Bend the underbody panelling down as far as required until you have easy access to the threaded joints for the brace plate -A-  .
   2. 9.2. Unscrew screws -1-  .
   3. 9.3. Remove brace plate.
      Fig 10: Removing Brace Plate Screws

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      NOTE: Transmission jack positioned incorrectly.

      • Risk of damage to ATF pan.

      → Use the entire surface of the ATF pan as the contact surface.

      Information 

      Make sure that the engine is positioned securely on the transmission jack. To do this, set the correct angle on the transmission jack.

10. Support the transmission and engine.
    1. 10.1. Support the transmission.
       1. 10.1.1. Position transmission jack -1-  under the ATF pan of the Porsche Doppelkupplung (PDK).
       2. 10.1.2. Secure the Porsche Doppelkupplung (PDK) with a tension strap.
    2. 10.2. Support the engine.
       1. 10.2.1. Position transmission jack -2-  under the engine of the vehicle.
          Fig 11: Positioning Transmission Jack

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11. Remove transmission brackets.
    1. 11.1. Remove transmission mount screw -1-  .
       1. 11.1.1. Unscrew nut -2-  from the transmission mount screw.
       2. 11.1.2. Remove transmission mount screw and nut.
    2. 11.2. Remove transmission bracket -A-  .
       1. 11.2.1. Unscrew screws -3-  .
       2. 11.2.2. Pull water tube holder -B-  off the transmission bracket.
       3. 11.2.3. Remove transmission bracket.
    3. 11.3. Remove transmission support -C-  .
       1. 11.3.1. Screw off nuts -4-  on the threaded bolts.
       2. 11.3.2. Remove transmission support.
          Fig 12: Removing Transmission Brackets

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          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.

12. Loosen cable duct for B+ line.
    1. 12.1. Lower the transmission until you have easy access to the threaded joints for the cable duct.
    2. 12.2. Unscrew external Torx screws -1-  .
    3. 12.3. Position the cable duct -A-  securely.
       Fig 13: Loosening Cable Duct For B+ Line

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13. Remove rpm sensor -1 -  .
    Fig 14: Removing RPM Sensor

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14. Remove coolant hoses.
    1. 14.1. Clamp coolant hoses. Use clamping pliers or a hose clamp 3093  to do this.
    2. 14.2. Position container for collecting coolant underneath.
    3. 14.3. Pull off coolant hose -1-  .
       Fig 15: Pulling Off Coolant Hose 1

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       1. 14.3.1. Remove spring clamp from the Henn coupling -arrow-  and pull off the coolant hose.
    4. 14.4. Pull off coolant hose -2-  .
       Fig 16: Pulling Off Coolant Hose 2

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       1. 14.4.1. Remove spring clamp from the Henn coupling -arrow-  and pull off the coolant hose.
15. Disconnect vent line and vacuum line.
    1. 15.1. Loosen and pull off vent line at the cable holder -arrows-  .
       Fig 17: Disconnecting Vent Line

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    2. 15.2. Disconnect vacuum line -1-  (-arrows-  ).
       Fig 18: Disconnecting Vacuum Line

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       NOTE: Mechanical overload of components

       • Component will be damaged irreparably

       → Observe guidelines for assembly and disassembly

       Information 

       • The splines of the transmission shaft must be removed completely from the flywheel before tipping off the transmission. 
       • If this is not done, the diaphragm spring on the flywheel will be damaged and the flywheel must be replaced. 
16. Remove Porsche Doppelkupplung (PDK) with transmission jack.
    1. 16.1. Unscrew fastening screws in the following sequence: -1, 2, 6, 5, 3, 4-  .
    2. 16.2. Pull the Porsche Doppelkupplung (PDK) forward until the transmission shaft is separated completely from the flywheel splines. 
    3. 16.3. Carefully lower the Porsche Doppelkupplung (PDK).
       Fig 19: Identifying PDK Screws

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       Information 

       Check that the guide sleeves between the transmission flange and engine flange remain in the engine flange.

       Information 

       • If the vehicle is placed on its wheels or moved in the workshop, the rear cross member must always be refitted beforehand. 
       • Without fitting the rear-axle cross member, the vehicle's suspension must be aligned after installing the engine or transmission. 

       Information 

       • Check the diaphragm spring on the flywheel for mechanical damage before installing it. 
       • A damaged flywheel must not be installed! 
17. Check diaphragm spring -1-  on the flywheel for damage.

    There must be no dents or mechanical damage! 

    1. 17.1. The flywheel must be replaced if the diaphragm spring is damaged -arrow-  .
       Fig 20: Locating Spring On Flywheel

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       Information 

       As an aid, use a stud or an old fastening screw with the screw head cut off.

18. Install rear axle cross member using the old screws.
    1. 18.1. To centre the cross member: Screw an auxiliary tool into the two outer aluminum threads  on the body.
    2. 18.2. Place a piece of wood between the cross member and engine flange to protect them.
    3. 18.3. Raise and position the cross member.
    4. 18.4. Screw the old screws into the two inner aluminum threads  and tighten them.
       Fig 21: Identifying Tool Bolts

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