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Home >> Porsche >> 2019 >> 718 Boxster Base, Automatic DCT Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 12 (37 Automatic Transmission - Actuator, Housing 2.5L -- 982 - BOXSTER/CAYMAN) >> SY, 3734N0 - Eliminating Transmission Symptoms - Reworking PDK Transmission (Repair Measures In The Event Of Various Symptoms/SY0213) >> Leaks On The PDK Transmission >> Reworking PDK Transmission

Reworking PDK Transmission

WARNING: This page is about a different variant/trim than selected.

Information 

To locate leaks on the PDK transmission, clean the entire affected area, spray it with leak-locating spray and carry out a test drive. See also

> 3734N0 ELIMINATING TRANSMISSION SYMPTOMS - REWORKING PDK TRANSMISSION (REPAIR MEASURES IN THE EVENT OF VARIOUS SYMPTOMS/SY0213)  - article on "Rework".

G14946709Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks in the short halfshaft flange/differential area 

-1- Leaks in the short halfshaft flange/differential area 

FES5: 39253 - Seal for short halfshaft flange

FES5: 39200 - Cover for final drive

Possible causes Remedial action
  • Sealing ring for short halfshaft flange damaged
 Replace sealing ring
> 392255 Replacing sealing ring for right halfshaft flange 
  • Double sealing ring damaged
 Replace double sealing ring
> 391555 Replacing double sealing ring 
  • Seal between housing cover and differential cover damaged
  
  • Housing screws loose
  
Only 911 Carrera with I-no. 221 "Regulated rear-differential lock": 
  • Sealing rings (O-rings) on housing flange damaged
  

Leaks at the threaded joint between rear part of housing and clutch housing 

-2- Leaks at the threaded joint between rear part of housing and clutch housing 

FES5: 37343 - Gear housing seal

Possible causes Remedial action
  • Seal damaged
 Replace PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 
  • Housing screws loose
  
G14946710Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks in the oil cooler area or around the oil lines for the oil cooler 

-3- Leaks in the oil cooler area or around the oil lines for the oil cooler 

FES5: 3862R - ATF line for oil cooler, return

FES5: 3862V - ATF line for oil cooler, supply

FES5: 38600 - ATF cooler

Possible causes Remedial action
  • Retaining brackets for oil lines loose/O-rings on oil lines for oil cooler damaged
 Replace retaining brackets or O-rings on oil lines for the oil cooler
> 386219 Removing and installing line for ATF cooling 
  • Oil line damaged
 Replace oil lines for the oil cooler
> 386219 Removing and installing line for ATF cooling 
  • Oil cooler leaking
 Replace oil cooler
> 386019 Removing and installing ATF cooler 

Leaks at the sensor connector (16-pin) 

-4- Leaks at the sensor connector (16-pin) 

FES5: 37344 - PDK connector

Possible causes Remedial action
  • O-ring damaged
 Replace PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 
  • Connector leaking
  

Oil leak from bleeder screw 

-5- Oil leak from bleeder screw 

FES5: 3734A - Hydraulic-oil inspection plug

Possible causes Remedial action
  • Oil leak from bleeder screw
 Replace PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 

Leaks at the sensor connector (20-pin) 

-6- Leaks at the sensor connector (20-pin) 

FES5: 37344 - PDK connector

Possible causes Remedial action
  • O-ring damaged
 Replace PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 
  • Connector leaking
  

Leak around the parking lock 

-7- Leak around the parking lock 

FES5: 37330 - Selector shaft sealing ring

Possible causes Remedial action
  • Sealing ring damaged
 Replace sealing ring
> 373355 Replacing sealing ring for parking lock shaft 

Leaks around the oil filler screw (clutch fluid) 

-8- Leaks around the oil filler screw (clutch fluid) 

FES5: 3734C - PDK transmission filler screw

Possible causes Remedial action
  • Replace oil filler screw (clutch fluid) and sealing ring
 Replace oil filler screw and sealing ring and correct oil level
> 370235 Checking and topping up ATF (clutch fluid) 

Leaks in the flanged shaft/long halfshaft flange area 

-9- Leaks in the flanged shaft/long halfshaft flange area 

FES5: 39254 - Sealing ring for long halfshaft flange

Possible causes Remedial action
  • Radial shaft seal damaged
 Replace sealing ring for left halfshaft flange
> 392519 Removing and installing left halfshaft flange 
  • Halfshaft-flange seal damaged
  
  • Halfshaft flange housing screws loose
  

Oil leak from inspection bore (centring plate) 

-10- Oil leak from inspection bore (centring plate) 

FES5: 37348 - Inspection bore on centring plate

Possible causes Remedial action
  • Radial shaft seal on drive shaft 2 - centring plate damaged
 Replace PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 
G14946711Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Oil leak from the hydraulic space bleeder 

-11- Oil leak from the hydraulic space bleeder 

FES5: 3747H - Hydraulic space bleeder

Possible causes Remedial action
  • Oil over-filled
 Check clutch fluid level and transmission oil level
> 370235 Checking and topping up ATF (clutch fluid)  > 399035 Checking and topping up oil for final drive (with transmission oil) 
If the clutch fluid level is too high and the transmission oil level is correct, correct the clutch fluid level as required.
If the clutch fluid level is too high and the transmission oil level is too low (>= 500 ml), check the PDK transmission for external leaks (e.g. around the transmission oil filler screw or drain plug), carry out repairs and then correct the oil/fluid levels.
If there are no external leaks visible, replace the PDK transmission > 373419 Removing and installing Porsche Doppelkupplung (PDK) 
  • Not enough anti-foam additive in clutch fluid
 Check clutch fluid level and transmission oil level
> 370235 Checking and topping up ATF (clutch fluid)  > 399035 Checking and topping up oil for final drive (with transmission oil) 
If both oil/fluid levels are correct, change the clutch fluid. Always follow the instructions on the container (shake, stir)
> 370255 Changing ATF (clutch fluid) 

Oil leak from the gearwheel set space bleeder 

-12- Oil leak from the gearwheel set space bleeder 

FES5: 3734R - Gear housing bleeder

Possible causes Remedial action
  • Oil over-filled
 Check clutch fluid level and transmission oil level
> 370235 Checking and topping up ATF (clutch fluid)  > 399035 Checking and topping up oil for final drive (with transmission oil) 
If  the clutch fluid level is correct and the transmission oil level is too high, correct the transmission oil level as required.
If  the clutch fluid level is too low and the transmission oil level is too high (>= 500 ml), check the PDK transmission for external leaks (e.g. around the clutch fluid filler screw or drain plug), carry out repairs and then correct the oil/fluid levels.
If there are no external leaks visible, replace the PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 
G14946712Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks around the oil pan/oil drain plug 

-13- Leaks around the oil pan/oil drain plug 

FES5: 37550 - ATF pan

FES5: 37560 - ATF-pan gasket

FES5: 3734D - PDK transmission drain plug

Information 

Traces of oil around the oil sump gasket  must only be classified as a "leak" if droplets are clearly visible. 

A suspected leak  can be caused by an ATF inspection or ATF top-up carried out earlier. To check this, refer to the vehicle documents or the vehicle history.

In this case, only clean around the seal on the oil pan.

Possible causes Remedial action
  • Traces of oil after opening the hydraulic space
 Clean the oil pan
  • Fastening screws on oil pan loose/oil pan seal damaged
 Replace oil pan and fastening screws
> 375519 Removing and installing ATF pan 
  • Oil drain plug (clutch fluid) loose or leaking
 Replace oil drain plug, correct oil level
> 370235 Checking and topping up ATF (clutch fluid) 
  • Oil drain plug (gearwheel set oil) loose or leaking
 Replace oil drain plug, correct oil level
> 399035 Checking and topping up oil for final drive (with transmission oil) 
G14946713Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks around the clutch bell-housing 

-14- Leaks around the clutch bell-housing 

FES5: 37530 - Seal for transmission housing

Possible causes Remedial action
  • Apparent preservative grease leak
 Check whether the leaking fluid is preservative grease or oil.
If residual grease is leaking out, no further measures are required.
  • Engine leaking
 Locate and correct leaks on the engine.
  • Radial shaft seal on coupling hub damaged
 Replace radial shaft seal
> 386955 Replacing sealing ring for Porsche Doppelkupplung (PDK) 
  • O-ring on clutch cover damaged
 Replace PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 

Oil leak from inspection bore for differential 

-15- Oil leak from inspection bore for differential 

FES5: 37349 - Inspection bore for differential

Possible causes Remedial action
  • Radial shaft seal on differential damaged
 Replace double sealing ring
> 391555 Replacing double sealing ring 
G14946714Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks around cover 

-16- Leaks around cover 

Possible causes Remedial action
  • Cover damaged
 Replace cover
> 374955 Replacing cover 

Leaks in the drive flange area (911 Carrera 4/911 Carrera 4S only) 

-17- Leaks in the drive flange area (911 Carrera 4/911 Carrera 4S only) 

FES5: 38700 - Drive shaft seal

Possible causes Remedial action
  • Radial shaft seal damaged
 Replace sealing ring for cardan flange
> 398255 Replacing sealing ring for cardan flange 
  • Main shaft leaking
  
G14946715Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks on gear wheel set heat exchanger - oil side 

-19- Leaks on gear wheel set heat exchanger - oil side 

FES5: 37721 - Gear wheel set heat exchanger - oil side

Possible causes Remedial action
  • Threaded joint loose
 Clean the transmission.
IF  the leaks occur again, replace the gear wheel set heat exchanger
  • Seal damaged
 > 377219 Removing and installing oil cooler for gear-wheel oil 
  • Gear wheel set heat exchanger leaking
  

Leaks on gear wheel set heat exchanger - water side 

-20- Leaks on gear wheel set heat exchanger - water side 

FES5: 37722 - Gear wheel set heat exchanger - water side

Possible causes Remedial action
  • Hoses leaking
 Clean the transmission.
IF  the leaks occur again, replace the gear wheel set heat exchanger
  • Gear wheel set heat exchanger leaking
 > 377219 Removing and installing oil cooler for gear-wheel oil 

Leaks on oil pipe for regulated rear-differential lock (only 911 Carrera with I-no. 221 "Regulated rear-differential lock") 

-21- Leaks on oil pipe for regulated rear-differential lock (only 911 Carrera with I-no. 221 "Regulated rear-differential lock") 

FES5: 39401 - Oil line for regulated rear-differential lock

Possible causes Remedial action
  • Seal damaged
 Clean the transmission.
IF  the leaks occur again, replace the oil pipe
> 397419 Removing and installing oil pipe for regulated rear-differential lock 
G14946716Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks on gear wheel set heat exchanger sensor 

-22- Leaks on gear wheel set heat exchanger sensor 

FES5: 37740 - Gear wheel set temperature sensor

Possible causes Remedial action
  • Seal damaged
 Clean the transmission.
IF  the leaks occur again, replace the gear wheel set heat exchanger sensor
> 377419 Removing and installing temperature sensor 


G14946717Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks in the short halfshaft flange/differential area 

-1- Leaks in the short halfshaft flange/differential area 

FES5: 39253 - Seal for short halfshaft flange

FES5: 39200 - Cover for final drive

Possible causes Remedial action
  • Sealing ring for short halfshaft flange damaged
 Replace sealing ring
> 392255 Replacing sealing ring for right halfshaft flange 
  • Double sealing ring damaged
 Replace double sealing ring
> 391555 Replacing double sealing ring 
  • Seal between housing cover and differential cover damaged
  
  • Housing screws loose
  

Leaks at the threaded joint between rear part of housing and clutch housing 

-2- Leaks at the threaded joint between rear part of housing and clutch housing 

FES5: 37343 - Gear housing seal

Possible causes Remedial action
  • Seal damaged
 Replace PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 
  • Housing screws loose
  
G14946718Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks in the oil cooler area or around the oil lines for the oil cooler 

-3- Leaks in the oil cooler area or around the oil lines for the oil cooler 

FES5: 3862R - ATF line for oil cooler, return

FES5: 3862V - ATF line for oil cooler, supply

FES5: 38600 - ATF cooler

Possible causes Remedial action
  • Retaining brackets for oil lines loose/O-rings on oil lines for oil cooler damaged
 Replace retaining brackets or O-rings on oil lines for the oil cooler
> 386219 Removing and installing line for ATF cooling 
  • Oil line damaged
 Replace oil lines for the oil cooler
> 386219 Removing and installing line for ATF cooling 
  • Oil cooler leaking
 Replace oil cooler
> 386019 Removing and installing ATF cooler 

Leaks at the sensor connector (16-pin) 

-4- Leaks at the sensor connector (16-pin) 

FES5: 37344 - PDK connector

Possible causes Remedial action
  • O-ring damaged
 Replace PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 
  • Connector leaking
  

Oil leak from bleeder screw 

-5- Oil leak from bleeder screw 

FES5: 3734A - Hydraulic-oil inspection plug

Possible causes Remedial action
  • Oil leak from bleeder screw
 Replace PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 

Leaks at the sensor connector (20-pin) 

-6- Leaks at the sensor connector (20-pin) 

FES5: 37344 - PDK connector

Possible causes Remedial action
  • O-ring damaged
 Replace PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 
  • Connector leaking
  

Leak around the parking lock 

-7- Leak around the parking lock 

FES5: 37330 - Selector shaft sealing ring

Possible causes Remedial action
  • Sealing ring damaged
 Replace sealing ring
> 373355 Replacing sealing ring for parking lock shaft 

Leaks around the oil filler screw (clutch fluid) 

-8- Leaks around the oil filler screw (clutch fluid) 

FES5: 3734C - PDK transmission filler screw

Possible causes Remedial action
  • Replace oil filler screw (clutch fluid) and sealing ring
 Replace oil filler screw and sealing ring and correct oil level
> 370235 Checking and topping up ATF (clutch fluid) 

Leaks in the flanged shaft/long halfshaft flange area 

-9- Leaks in the flanged shaft/long halfshaft flange area 

FES5: 39254 - Sealing ring for long halfshaft flange

Possible causes Remedial action
  • Radial shaft seal damaged
 Replace sealing ring for left halfshaft flange
> 392255 Removing and installing sealing ring for long halfshaft flange 
  • Halfshaft-flange seal damaged
  
  • Halfshaft flange housing screws loose
  

Oil leak from inspection bore (centring plate) 

-10- Oil leak from inspection bore (centring plate) 

FES5: 37348 - Inspection bore on centring plate

Possible causes Remedial action
  • Radial shaft seal on drive shaft 2 - centring plate damaged
 Replace PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 
G14946719Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Oil leak from the hydraulic space bleeder 

-11- Oil leak from the hydraulic space bleeder 

FES5: 3747H - Hydraulic space bleeder

Possible causes Remedial action
  • Oil over-filled
 Check clutch fluid level and transmission oil level
> 370235 Checking and topping up ATF (clutch fluid)  > 399035 Checking and topping up oil for final drive (with transmission oil) 
If the clutch fluid level is too high and the transmission oil level is correct, correct the clutch fluid level as required.
If the clutch fluid level is too high and the transmission oil level is too low (>= 500 ml), check the PDK transmission for external leaks (e.g. around the transmission oil filler screw or drain plug), carry out repairs and then correct the oil/fluid levels.
If there are no external leaks visible, replace the PDK transmission > 373419 Removing and installing Porsche Doppelkupplung (PDK) 
  • Not enough anti-foam additive in clutch fluid
 Check clutch fluid level and transmission oil level
> 370235 Checking and topping up ATF (clutch fluid)  > 399035 Checking and topping up oil for final drive (with transmission oil) 
If both oil/fluid levels are correct, change the clutch fluid. Always follow the instructions on the container (shake, stir)
> 370255 Changing ATF (clutch fluid) 

Oil leak from the gearwheel set space bleeder 

-12- Oil leak from the gearwheel set space bleeder 

FES5: 3734R - Gear housing bleeder

Possible causes Remedial action
  • Oil over filled
 Check clutch fluid level and transmission oil level
> 370235 Checking and topping up ATF (clutch fluid)  > 399035 Checking and topping up oil for final drive (with transmission oil) 
If the clutch fluid level is correct and the transmission oil level is too high, correct the transmission oil level as required
If the clutch fluid level is too low and the transmission oil level is too high (>= 500 ml), check the PDK transmission for external leaks (e.g. around the clutch fluid filler screw or drain plug), carry out repairs and then correct the oil/fluid levels.
If there are no external leaks visible, replace the PDK transmission > 373419 Removing and installing Porsche Doppelkupplung (PDK) 
G14946720Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks around the oil pan/oil drain plug 

-13- Leaks around the oil pan/oil drain plug 

FES5: 37550 - ATF pan

FES5: 37560 - ATF-pan gasket

FES5: 3734D - PDK transmission drain plug

Information 

Traces of oil around the oil sump gasket  must only be classified as a "leak" if droplets are clearly visible. 

A suspected leak  can be caused by an ATF inspection or ATF top-up carried out earlier. To check this, refer to the vehicle documents or the vehicle history.

In this case, only clean around the seal on the oil pan.

Possible causes Remedial action
  • Traces of oil after opening the hydraulic space
 Clean the oil pan
  • Fastening screws on oil pan loose/oil pan seal damaged
 Replace oil pan and fastening screws
> 375519 Removing and installing ATF pan 
  • Oil drain plug (clutch fluid) loose or leaking
 Replace oil drain plug, correct oil level
> 370235 Checking and topping up ATF (clutch fluid) 
  • Oil drain plug (gearwheel set oil) loose or leaking
 Replace oil drain plug, correct oil level
> 399035 Checking and topping up oil for final drive (with transmission oil) 
G14946721Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks around the clutch bell-housing 

-14- Leaks around the clutch bell-housing 

FES5: 37530 - Seal for transmission housing

Possible causes Remedial action
  • Apparent preservative grease leak
 Check whether the leaking fluid is preservative grease or oil
If residual grease is leaking out, no further measures are required
  • Engine leaking
 Locate and correct leaks on the engine.
  • Radial shaft seal on coupling hub damaged
 Replace radial shaft seal
> 386955 Replacing sealing ring for Porsche Doppelkupplung (PDK) 
  • O-ring on clutch cover damaged
 Replace PDK transmission
> 373419 Removing and installing Porsche Doppelkupplung (PDK) 

Oil leak from inspection bore for differential 

-15- Oil leak from inspection bore for differential 

FES5: 37349 - Inspection bore for differential

Possible causes Remedial action
  • Radial shaft seal on differential damaged
 Replace double sealing ring
> 391555 Replacing double sealing ring 
G14946722Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks around cover 

-16- Leaks around cover 

Possible causes Remedial action
  • Cover damaged
 Replace cover
> 374955 Replacing cover 

Leaks in the drive flange area 

-17- Leaks in the drive flange area 

FES5: 38700 - Drive shaft seal

Possible causes Remedial action
  • Radial shaft seal damaged
 Replace sealing ring for cardan flange
> 398255 Replacing sealing ring for cardan flange 
  • Main shaft leaking
  
G14946723Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks on gear wheel set heat exchanger - oil side 

-19- Leaks on gear wheel set heat exchanger - oil side 

FES5: 37721 - Gear wheel set heat exchanger - oil side

Possible causes Remedial action
  • Threaded joint loose
 Clean the transmission.
IF  the leaks occur again, replace the gear wheel set heat exchanger
  • Seal damaged
 > 377219 Removing and installing oil cooler for gear-wheel oil 
  • Gear wheel set heat exchanger leaking
  

Leaks on gear wheel set heat exchanger - water side 

-20- Leaks on gear wheel set heat exchanger - water side 

FES5: 37722 - Gear wheel set heat exchanger - water side

Possible causes Remedial action
  • Hoses leaking
 Clean the transmission.
IF  the leaks occur again, replace the gear wheel set heat exchanger
  • Gear wheel set heat exchanger leaking
 > 377219 Removing and installing oil cooler for gear-wheel oil 
G14946724Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Leaks on gear wheel set heat exchanger sensor 

-22- Leaks on gear wheel set heat exchanger sensor 

FES5: 37740 - Gear wheel set temperature sensor

Possible causes Remedial action
  • Seal damaged
 Clean the transmission.
IF  the leaks occur again, replace the gear wheel set heat exchanger sensor
> 377419 Removing and installing temperature sensor 

Locating leaks 

Information 

To determine the cause of the leak, the following procedure involves cleaning the PDK transmission, test-driving the vehicle and then performing a visual inspection.

  1. Check all possible leakage points (cover stoppers, etc.) for traces of leaking oil, see also

    > 3734N0 ELIMINATING TRANSMISSION SYMPTOMS - REWORKING PDK TRANSMISSION (REPAIR MEASURES IN THE EVENT OF VARIOUS SYMPTOMS/SY0213) - article on "Rework"

  2. Document the nature of the oil leak (source of the leak, oil dripping, drops of oil forming, etc.) for PQIS using digital photos.
  3. Clean the transmission:

    Carefully clean leaking joints with brake cleaner and a clean cloth and then blow out the gap with compressed air.

  4. Spray the gap and all possible leakage points with leak-locating spray.
  5. Perform a test drive until the engine oil and coolant are at least at operating temperature.

    Then perform a visual inspection of the transmission and document any possible sources of leaks that you find with digital photos for PQIS.

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