Installing Double Sealing Ring

Information 

Assembly tool for double sealing ring:

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1. > 9358 - Pressure piece 
2. Double sealing ring
3. >9359 - Assembly fixture 

The > 9359/1 - adapter plate  is also required for installing the double sealing ring on the Boxster/Cayman.

1. Clean the sealing surface of the sealing rings and check for damage.

   Information 

   • Check that the double sealing ring is seated correctly on the tool. 
   • The groove in the special tool must fit completely in the larger sealing ring. 
   • The sealing ring is fitted dry. Do not touch the sealing lip! 
2. Slide double sealing ring -2-  onto > 9358 - pressure piece-1-  .

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3. Fit double sealing ring.
   1. 3.1 Position assembly fixture -1-  with pressure piece -2-  and double sealing ring -3-  (-arrow-  ).

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      Information 

      Two of the aluminium screws that were unscrewed when removing the housing cover can be used as securing screws.

   2. 3.2 Secure assembly fixture -1-  to the housing flange using two aluminium screws -2-  .
   3. 3.3 Screw in pressure piece with double sealing ring clockwise as far as it will go -arrow-  .
4. Leave assembly fixture -1-  fitted for three minutes.
5. Then remove assembly fixture. The sealing ring must end flush with the "aluminium edge".

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   Information 

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   1. Bearing ring
   2. Spacer ring
   • Be careful with the spacer ring behind the bearing ring during removal and installation. 
   • The original bearing ring must be re-installed. 
6. Insert spacer ring -2-  with bearing ring -1-  .

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7. Replace circlips on both halfshaft flanges.

   Information 

   • Check that the sealing ring is seated correctly on the tool. 
   • The sealing ring is fitted dry. Do not touch the sealing lip! 
8. Replace sealing ring on the housing neck.
   1. 8.1 Fit new sealing ring -1-  on > 9738 - pressure piece-2-  .
9. Drive sealing ring -1-  into the housing neck -3-  .
   1. 9.1 Press in sealing ring -1-  using pressure piece -2-  so that it is fitted securely in the housing neck -3-  .
   2. 9.2 Hold the tool at the end position for one minute and press again carefully if necessary.

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10. Check long flanged shaft -1-  for burrs and sharp edges on the transmission end of the shaft -arrow-  and deburr if necessary.

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    Information 

    Assembly tool > 9357 - protective sleeve, two-piece  for long flanged shaft:

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    1. Protective sleeve
    2. Storage and transport protection
    3. Locking screw
    4. Mounting cone
11. Slide protective sleeve -3-  onto the long flanged shaft -1-  .

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12. Push long flanged shaft -1-  with protective sleeve -2-  in carefully and straight -arrow-  .

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13. Secure the long flanged shaft -1-  with an O-ring -2-  .

    Securing long flanged shaft

14. Insert differential -1-  into the housing.

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    Information 

    • The aluminium screws for the differential housing cover must be replaced. 
    • The aluminium screws for the Porsche Doppelkupplung (PDK) must be tightened using the yield-point-controlled tightening method. 
    • The special tool:  > 9768 - Electronic torque wrench must be used for this purpose. 
    • To ensure that the screws are tightened uniformly, the corresponding tightening setting "light, medium or hard" must always be used. 
15. Install differential housing cover.
    1. 15.1 Insert new O-ring on the housing cover and check that it is seated correctly.
    2. 15.2 Grease O-ring with Kluber Syntheso Glep.
    3. 15.3 Fit housing cover and secure with new aluminium screws evenly in the specified tightening sequence.
    4. 15.4 Tighten fastening screws according to the specified tightening sequence. > Initial tightening + yield strength 6 Nm (4.5 ftlb.) 
    Fig 1: Differential Screws Tightening Sequence

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16. Replace sealing ring on the short halfshaft flange.

    > 392255 REPLACING SEALING RING ON RIGHT HALFSHAFT FLANGE 

17. Fit the short halfshaft flange with a new circlip.