Installing Double Clutch Transmission

Information 

Replace flange screws if necessary.

Information 

After replacing the Porsche Doppelkupplung (PDK) or after carrying out repairs in the Porsche Doppelkupplung (PDK), the transmission control unit must be calibrated using the PIWIS Tester  .

Information 

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

1. Check whether input shaft is fitted with a circlip on the double clutch shaft splines. If not:
   1. 1.1 Coat shaft splines -3-  with Longtime 3EP  .
   2. 1.2 Carefully fit input shaft -1-  until the circlip -2-  clips into place -arrow-  .

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   Input shaft

2. Lift the double clutch transmission.

   Make sure that the guide sleeves are located in the engine flange.

   When lifting the transmission, make sure that no connectors or cables are trapped.

3. Lift up and mount double clutch transmission.
   1. 3.1 Adjust the angle of the transmission jack so that the transmission flange and engine flange are parallel.
   2. 3.2 Make sure that no lines are trapped between the transmission flange and engine flange.
   3. 3.3 Fit double clutch transmission.

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   Recommended tools for flange screws

   A	Recommended tool for screw 6
   B	Recommended tool for screws 4 and 5
   C	Recommended tool for screws 1, 2 and 3
   1	Torx socket-wrench insert E18, 1/2-inch
   2	Universal joint, 1/2-inch
   3	Extension, 1/2-inch
   4	Change-over ratchet, 1/2-inch
   5	> VAS 6953 - Ring Socket Insert, E18
   6	> V.A.G 1332 - Torque wrench, 40-200 Nm (30-148 ftlb.)

4. Tighten screws in the specified sequence -6 to 1-  to >Tightening torque 85 Nm (62.7 ftlb.)  .
   Fig 1: Double Clutch Transmission Screws Tightening Sequence

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   Double clutch transmission screws

   Information 

   • The coolant hoses must lock with an audible click when pushed into the plug-in couplings. 
5. Secure coolant hoses -1-  .
   1. 5.1 Push on coolant hoses -1-  . Spring clamps -arrow-  must engage securely.

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   Connection point for coolant hoses

6. Secure disc valve holder on the transmission.

   > Tightening torque 12 Nm (8.9 ftlb.) 

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   Thermal management disc valve

7. Fit vacuum line -1-  .

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   Vacuum line on disc valve

8. Secure wiring harness on double clutch transmission.
   1. 8.1 Right side:  Plug in cable plug -5-  and secure wiring harness on the double clutch transmission -Arrows-  . Screw in and tighten screws -3 and 4-  .

      -3-  > Tightening torque 13 Nm (9.6 ftlb.) 

      -4-  > Tightening torque 40 Nm (29.5 ftlb.) 

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      B+ line in cable guide

   2. 8.2 Left side:  Plug in cable plugs -1, 2 and 3-  . Clip in connector housing -4-  and wiring harness -Arrows-  .

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   Wiring harness on double clutch transmission

9. Install transmission support and transmission bracket.
   1. 9.1 Insert transmission support -5-  and fit nuts -4-  .
   2. 9.2 Fit transmission bracket -3-  on transmission mount.
   3. 9.3 Carefully lift the double clutch transmission to its end position using the transmission Jack.

      Make sure that the studs on the transmission support -5-  slide in through the bores of the transmission bracket -3-  and transmission mount.

   4. 9.4 Fit and tighten screws -1-  and nuts -2-  .

      Screws -1-  : >Initial tightening 30 Nm (22.1 ftlb.)  + >Torque angle 60° 

      Nuts -2-  : >Initial tightening 30 Nm (22.1 ftlb.)  + >Torque angle 60° 

      Nuts -4- > Initial tightening 30 Nm (22.1 ftlb.)  + >Torque angle 60° 

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   Transmission support and transmission bracket

10. Secure B+ line.
    1. 10.1 Tighten nut -2-  and close cap -1-  .

       > Tightening torque 23 Nm (17 ftlb.) 

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    Connection point for B+ line

11. Connect electric plug connections on the double clutch transmission.
    1. 11.1 Plug in three cable plugs -1-  .

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       Cable plugs on double clutch transmission

    2. 11.2 Plug in cable plug for pulse sender for engine speed -1-  .

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    Cable plug for pulse sender

12. Remove transmission jack from under the double clutch transmission and engine.
    1. 12.1 Loosen restraining strap.
    2. 12.2 Lower and remove the transmission jack.
    3. 12.3 Lower and remove the transmission jack.
13. Fit drive shafts on transmission side.
    1. 13.1 Remove tie-wrap.
    2. 13.2 Fit and tighten screws -Arrows-  on the drive shaft flange with the plates -1-  .

       > Initial tightening 40 Nm (29.5 ftlb.) 

       > Final tightening torque angle + 110° 

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

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    Drive shafts

14. Vehicles with PDCC:  Fit PDCC lines.
    1. 14.1 Position bracket for PDCC lines -A-  .
    2. 14.2 Fit and tighten screws -1-  .

       > Tightening torque 10 Nm (7.5 ftlb.) 

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       Removing and fitting bracket for PDCC lines

    3. 14.3 Clip PDCC lines -A-  into the brackets -1-  .

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       Bracket for PDCC lines

    4. 14.4 Fit and tighten union nuts -1-  .

       > Tightening torque 28 Nm (21 ftlb.) 

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       Threaded joint for lines

    5. 14.5 Push hose -2-  onto the line -1-  and tighten the clamp.

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PDCC intake pipe