NHTSA ID Number: 10109278
Manufacturer Communication Number: 122-G7E5R-06
TSB/Document Date: 2017-08-01
Summary
Concerns: PDK transmission Information: There is a possibility of moisture condensing in the vent line of the PDK transmission under certain environmental influences and getting into the inside of the PDK transmission through the ventilation connections. The transmission oil/water emulsion created as a result of this is deposited on the inner contacts of the multiple plug connection for the PDK transmission and causes electric shunt circuits there. If this happens, the PDK transmission can malfunction, e.g. switch to the reduced driving program (limp-home mode).
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999.072.866.01
Hexagon round-head bolt, M12 x 1.5 x 95
– Rear-axle cross member to body
4 ea.
999.084.648.01
Hexagon nut, M10
– Transmission side member to body
2 ea.
900.385.164.01
1 ea.
Hexagon round-head bolt, M12 x 1.5 x 140
– Transmission side member to transmission
999.086.009.02
1 ea.
Torx nut, M12 x 1.5
– Transmission side member to transmission
999.072.869.01
Hexagon-head bolt, M12 x 1.5 x 40
– Diagonal brace to rear-axle cross member
2 ea.
999.073.443.01
Combination screw, M12 x 1.5 x 40
– Diagonal brace to body
2 ea.
997.111.240.30
Clip
– Tailpipe on exhaust system
2 ea.
Also required:
000.043.301.47
Antifreeze (1-litre container)
approx. 0.5
litres per
vehicle
Also required for vehicles without PDCC:
999.084.123.09
Hexagon nut, M10
– Connecting link to anti-roll bar
2 ea.
Also required for vehicles with PDCC (I-no. 031, 352):
999.084.445.01
Hexagon nut, M12 x 1.5
– PDCC actuator to anti-roll bar
2 ea.
000.043.206.56
Pentosin CHF 202 (1-litre container)
approx. 0.5
litres per
vehicle
* During this measure, two short breather hoses will be fitted on the PDK transmission instead of the vent
line. One of these breather hoses is an existing part of the vent line to be replaced and must be re-used
following removal.
The repair kit therefore only contains one new breather hose.
Tools:
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•
Nr.21 - Disassembly tool
Workshop lift, e.g. WE1222 - transmission and unit jack Junior Jack 0.5 together with VAS
6867 - mounting plate
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•
•
•
•
•
Work
Procedure:
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Nr.89 Pos.5 - Torque screwdriver (1.5–3 Nm/1–2 ftlb.)
Nr.90 Pos.2 - Torque wrench (4–20 Nm/3–15 ftlb.)
Nr.90 Pos.3 - Torque wrench (10–60 Nm/7.5–44 ftlb.)
Nr.90 Pos.4 - Torque wrench (25–130 Nm (19–96 ftlb.)
Nr.88 - Torque angle torque wrench or 9768 - Electronic torque wrench, 2-100 Nm/1.5-74
ftlb.
9696 - Filling device
Remedial Action 1 is the Precondition
•
PDK transmission removed (already removed during Remedial action 1 – Remove condensation on
multiple plug connection for PDK transmission Technical Information '3734 PDK transmission:
Fault codes P172D, P17F1 P17F2, P18CA, P18CB (65/13)')
Replace vent line for PDK transmission with two short breather hoses
1
Remove vent line.
1.1
Open line bracket Removing vent line -2and remove vent line Removing vent line
-1-.
Information
The line brackets for the original vent line are
no longer required after conversion and have
to be removed.
1.2
Unclip line bracket Removing vent line -2from the PDK transmission and remove it.
1.3
Pull vent line Removing vent line -1- off ventilation connection for gear wheel set
Removing vent line -3- and off ventilation connection for clutch chamber Removing vent
line -4-.
1.4
Remove vent line Removing vent line -1-.
Removing vent line
Information
The breather hose fitted at the lower end of the vent line (90° angled pipe) must be re-used as part of this
procedure.
Make sure that the vent hose is not damaged during removal.
2
Disconnect breather hose from vent line.
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Information
The line brackets for the original vent line are no longer required after conversion and have to
be removed.
2.1
Carefully cut tie-wrap on the line bracket
Removing breather hose -2- and remove line
bracket.
2.2
Carefully pull breather hose (90° angled pipe)
Removing breather hose -1- off the vent
line Removing breather hose -3- and store
it safely.
Removing breather hose
3
Fit breather hose for gear wheel set.
Information
The cable duct remains on the vehicle when
the PDK transmission is removed.
As an example, the figure shows the required
installation position of the breather hose after
fitting the cable duct while re-installing the
PDK transmission.
3.1
3.2
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Position the breather hose (90° angled pipe)
Installing breather hose for gear wheel set
-1- you removed previously from the vent line
on the PDK transmission as shown in figure
Installing breather hose for gear wheel set.
The breather hose must point to the lower
right in direction of travel.
Installing breather hose for gear wheel set
Slide the breather hose Installing breather
hose for gear wheel set -1- as far as it will go onto the ventilation connection for the gear
wheel set Installing breather hose for gear wheel set -2- ( Installing breather hose
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for gear wheel set -arrow-). When re-installing the PDK transmission, make sure that the
breather hose Installing breather hose for gear wheel set -1- is routed under the cable
duct Installing breather hose for gear wheel set -3-.
4
Fit breather hose for clutch chamber.
4.1
Position new breather hose Installing
breather hose for clutch chamber -1- from
the repair kit, Part No. 000.043.110.30,
on the PDK transmission as shown in
figure Installing breather hose for clutch
chamber. The breather hose must point to
the lower left in direction of travel and
must be routed under the vacuum line
Installing breather hose for clutch chamber
-3-. To do this, carefully press the vacuum
line to one side.
4.2
Slide the breather hose Installing breather
hose for clutch chamber -1- as far as it will go
onto the ventilation connection for the clutch
chamber Installing breather hose for clutch
chamber -2- ( Installing breather hose for
clutch chamber -arrow-).
Installing breather hose for clutch chamber
Subsequent work
1
Install PDK transmission Workshop Manual '373419 Removing and installing Porsche![]()
Doppelkupplung (PDK)'.
2
Check engine coolant level and add coolant if necessary Workshop Manual '190101 Checking the
cooling system'.
3
Install cover for rear underbody Workshop Manual '519419 Removing and installing cover for
rear underbody'.
Then, carry out Remedial action 3 and re-program the PDK control unit.
Remedial action 3: Re-programming PDK control unit
Information
The procedure described here is based on the PIWIS Tester II software version 13.100.
The PIWIS tester instructions take precedence and in the event of a discrepancy these are the
instructions that must be followed. Deviations may occur with later software versions, for example.
Tools:
•
9818 - PIWIS Tester II with software version 13.100 (or higher) installed
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Battery Charger/Power Supply - Suitable for AGM Type batteries, recommended current rating of
70A fixed voltage 13.5V to 14.5V. Refer to Equipment Information EQ-1105.
Work
Procedure:
NOTICE
Fault entry in the fault memory and control unit programming aborted due to low voltage.
•
Increased current draw during diagnosis or control unit programming can cause a drop in voltage, which
can result in one or more fault entries and the abnormal termination of the programming process.
Before starting control unit programming, connect a battery charger or power supply, suitable for AGM
type batteries, recommended current rating of 70A fixed voltage 13.5V to 14.5V to the vehicle.
NOTICE
Control unit programming will be aborted if the Internet connection is unstable.
•
An unstable Internet connection can interrupt communication between PIWIS Tester II and the vehicle
communication module (VCI). As a result, control unit programming may be aborted.
During control unit programming, always connect PIWIS Tester II to the vehicle communication module
(VCI) via the USB cable.
NOTICE
Control unit programming will be aborted if the vehicle key is not recognized
•
If the vehicle key is not recognized in vehicles with Porsche Entry & Drive, programming cannot be started
or will be interrupted.
Switch on the ignition using the original vehicle key. To do this, replace the original vehicle key in the
ignition lock with the plastic key fob if it was previously removed at the start of this procedure.
Information
When the PDK control unit is programmed, the DME control unit is also re-programmed automatically.
Total programming time is approx. 12 minutes.
Preliminary work
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Connect a battery charger or power supply,
suitable for AGM type batteries, recommended
current rating of 70A fixed voltage 13.5V to
14.5V. First connect the positive cable of the
charger to the positive terminal of the battery and
then connect the negative cable of the charger to
the ground point for jump-lead starting External
power supply.
External power supply
2
Switch on the ignition using the original driver's key. On vehicles with “Porsche
Entry & Drive”,
do this by replacing the control panel in the ignition lock with the original driver's key if necessary.
3
9818 - PIWIS Tester II with software version 13.100 (or higher) installed must be connected to
the vehicle communication module (VCI) via the USB cable. Then, connect the communication
module to the vehicle and switch on the PIWIS Tester.
Re-programming PDK control unit
1
On the PIWIS Tester start screen, call up the 'Diagnostics' menu and select vehicle type
'911' '991'.
The diagnostic application is then started and the control unit selection screen is populated.
2
Select the control unit 'Transmission control'
in the control unit selection screen ( “Overview”
menu) and press •>>“ to confirm your selection.
Control unit selection - Transmission control
3
When the question “Create Vehicle Analysis Log (VAL)?” appears, either press •F12“ to create a
VAL or press •F11“ if you do not want to create a VAL.
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Press •>>“ to acknowledge the message informing you that campaigns for the vehicle are stored
in the PIWIS information system.
5
Once the PDK control unit has been found, select the 'Programming' menu.
6
Select the 'Automatic programming'
function and press •>>“ to confirm your selection
Automatic programming.
Automatic programming
Information
Read and follow the information and instructions on the PIWIS Tester during the guided
programming sequence. Then press •>>“ to continue.
First the DME control unit and then the PDK control unit is programmed using a new data record. Total
programming time is approx. 12 minutes.
The control units are then re-coded automatically.
Do not interrupt programming and coding.
Once the control units have been re-coded, you will be prompted to switch the ignition off and then back
on again after approx. 10 seconds.
When programming is complete, the message “Programming was completed successfully” will
be displayed.
Once programming is completed successfully (message “Programming was completed successfully”),
carry out the work described below.
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If programming is interrupted (e.g. due to a voltage drop or if communication is aborted, etc.)
or if programming could not be carried out successfully (error message "Programming unsuccessful"), programming must be repeated.
•
If coding is not carried out successfully during the guided programming sequence, the DME and
PDK control units must be re-coded again separately once the guided programming sequence
is complete. To do this, select the control units "DME" and "Transmission control" in the control unit
selection screen ( "Overview" menu) and press •>>“ to confirm your selection. Once the control
units have been found, select the “Codings/adaptations” menu and re-code the control units using
the "Automatic coding" function.
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Once the control unit has been programmed and coded successfully, press •>>“ to continue.
9
Select the 'Overview' menu and press •“ to confirm your selection.
2
Once the DME control unit has been found and is displayed in the overview, select the 'Maintenance/repairs' menu.
3
Select menu item 'Adaptations' and press
•>>“ to confirm your selection DME - Adaptations.
DME - Adaptations
4
Comply with the displayed preconditions
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•
•
•
Engine off
Ignition on
Accelerator pedal not pressed
Parking brake on
and press •>>“ to confirm.
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Select the 'Throttle valve' function so that
the corresponding text line turns blue and press
•F8“ to start throttle valve adaptation Throttle
valve adaptation.
Throttle valve adaptation
6
Follow the instructions on the PIWIS Tester while throttle valve adaptation is being performed.
Once throttle valve adaptation is complete, a tick will appear in the "Value" field on the PIWIS Tester
display.
If throttle valve adaptation is not completed successfully, adaptation must be repeated.
7
Press •F8“ (“Stop”) to end throttle valve adaptation.
8
Press •
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TSB/Document ID: 122-G7E5R-06
Replacement Service Bulletin Number:
MFR Communication Date: 2013-12-11
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN:AUTOMATIC TRANSMISSION
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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