NHTSA ID Number: 10117425
Manufacturer Communication Number: 122-L5R7Q-05
TSB/Document Date: 2017-09-14
Summary
Concerns: Lower suspension arms for front axle Information: The front axle of the Porsche 918 Spyderwas fitted with lower suspension arms from a batch whose durability cannot be guaranteed due to amanufacturing error.
similar) access ramps.
2.2
Remove underbody covers and fit mounting plates 9002 - Lifting platform holders,
Workshop Manual '518119 Removing and installing jacking points'.
2.3
Jack and raise the vehicle at the mounting plates.
3
Remove both front wheels Workshop Manual '440519 Removing and installing wheel'.
4
Remove front wheel housing liner (front part) at the left and right Workshop Manual '50561901
Removing and installing front wheel housing liner (front part)'.
5
Remove front wheel housing liner (rear part) at the left and right Workshop Manual '50561905
Removing and installing front wheel housing liner (rear part)'.
6
Remove cover for center underbody (at the sides) at the left and right Workshop Manual
'51931901 Removing and installing cover for centre underbody (at the sides)'.
7
Remove cover for front underbody Workshop Manual '519219 Removing and installing cover for
front underbody'.
8
Remove cover for center underbody Workshop Manual '51931900 Removing and installing cover
for centre underbody'.
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Information
•
9
Do not open the brake hydraulic system (brake line remains connected).
Remove front brake caliper at the left and right Workshop Manual '473919 Removing and
installing front brake calliper'.
Suspend the brake caliper on the vehicle using a tie-wrap, for example.
10 Remove front PCCB brake disc at the left and right Workshop Manual '465119 Removing and
installing front PCCB brake disc'.
Replacing lower suspension arms for front axle
Procedure:
1
Remove lower suspension arm for front axle at the left.
1.1
Loosen and remove nut Loosening tie rod
-2- on the wheel carrier.
Remove bolt Loosening tie rod -3- on the
wheel carrier and pull out tie rod Loosening
front connecting link at the top -1-out of the
wheel carrier.
Loosening tie rod
1.2
Loosen and remove nut Loosening
front connecting link at the top -3- at
the connecting link Loosening front
connecting link at the top -1-.
Remove connecting link from the anti-roll bar
Loosening front connecting link at the top
-2- and turn it to the side.
Loosening front connecting link at the top
NOTICE
Damage to the drive shaft
•
Bellows can be overstrained or crack
•
Damage to the tripod joint
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Support loosened wheel carrier using a suitable engine jack.
Carefully pull the wheel carrier outwards in order to remove the suspension arms.
Do NOT attempt to remove drive shafts!
NOTICE
Damage to ride height sensors and linkage
Take great care not to damage
Verify correct orientation of linkage
1.3
Loosen and remove nut Loosening upper
suspension arm -2- on the wheel carrier.
Remove bolt Loosening upper suspension
arm -3- on the wheel carrier Loosening
upper suspension arm -4- and carefully pull
the wheel carrier outwards away from the
upper suspension arm Loosening spring
strut -1-. Move the upper suspension arm
upward so that it clears the wheel carrier.
1.4
Support the wheel carrier using a suitable
transmission carrier.
Loosening upper suspension arm
1.5
Loosen and unscrew nut Loosening spring
strut -3- on the spring strut Loosening
spring strut -1-.
Pull out and remove the bolt Loosening
spring strut -4- on the lower suspension arm
Loosening spring strut -2-.
Loosening spring strut
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1.6
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Loosen and unscrew fastening nut Lower
suspesion arm on wheel carrier -2-for the ball
joint for the lower suspension arm Lower
suspesion arm on wheel carrier -1- on the
wheel carrier.
Press the ball joint out of the wheel carrier.
If necessary, loosen the ball joint from the
wheel carrier by gently tapping with a plastic
hammer.
Lower suspesion arm on wheel carrier
1.7
2
Loosen and unscrew fastening screws
Lower suspension arm on front-axle carrier
-1- for the lower suspension arm on the
front-axle carrier.
Pull lower suspension arm out of the front-axle
carrier and remove it.
Install new lower suspension arm for front axle at the
left.
Information
Always use new fastening screws and lock nuts from
the set of fastening parts.
2.1
Lower suspension arm on front-axle carrier
Push lower suspension arm into the front-axle carrier.
Install the bolts Lower suspension arm on front-axle carrier -1- for the lower suspension
arm on the front-axle carrier and tighten using the three-step tightening procedure:
•
•
•
Step 1 – Initial tightening to 80 Nm (59 ft-lb.):
Step 2 – Loosening 180°
Step 3 – Finally tightening to 80 Nm (59 ft-lb.):
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Lower suspension arm on front-axle carrier
2.2
Apply a thin coat of Autol Top 2000 grease,
Part No. 000.043.981.00, to the conical
area on the ball joint Greasing conical area
-1- for the lower suspension arm.
Greasing conical area
2.3
Carefully press the ball joint Lower
suspension arm on wheel carrier -1- for the
suspension arm into the tapered bore on the
wheel carrier.
Initaially install the nut Lower suspension
arm on wheel carrier -2- for ball joint by only a
few turns.
Lower suspension arm on wheel carrier
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2.4
Press lower suspension arm Securing
spring strut -2- together with the wheel
carrier using the transmission and engine
jack until the spring strut Securing spring
strut -1- is at the correct installation position
on the suspension arm.
Install bolt Securing spring strut -4through the wheel carrier and spring strut and
secure with the nut Securing spring strut
-3-.
Tightening torque 55 Nm (41 ftlb.)
2.5
Remove transmission and engine jack.
ENU
AF01
4
Securing spring strut
NOTICE
Incorrect positioning of the horizontal banner arm (lever arm) for level sensor
•
Damage to the level sensor
•
Damage to the connecting link for the level sensor
Make sure that the ride height sensors and linkage is pointing outwards towards the wheel.
Do not bend the horizontal banner arm (lever arm) and connecting link or press them aside.
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Verify the ride height sensor and Installation position of level sensor -1- is oriented
correctly (Top illustration).
Installation position of level sensor
2.7
Install the bolt Securing upper suspension
arm -3- on the wheel carrier Securing
upper suspension arm -4- and upper
suspension arm Securing upper
suspension arm -1- and secure with the nut
Securing upper suspension arm -2-.
Tighten to 42 Nm (31 ft.-lb.)
2.8
Position connecting link Securing front
connecting link -1- on the anti-roll bar
Securing front connecting link -2- and
secure with the fastening nut Securing
front connecting link -3- using the two-step
tightening procedure:
•
•
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Securing upper suspension arm
Step 1 – Initial tightening: Tightening torque 40 Nm (30 ftlb.)
Step 2 – Final tightening: Torque angle 30°
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Securing front connecting link
2.9
Position tie rod Securing tie rod -1- on the
wheel carrier. Install bolt Securing tie rod
-3- and secure with nut Securing tie rod
-2-.
Tightening torque 42 Nm (31 ftlb.)
2.10
Tighten nut Lower trailing arm on wheel
carrier -2- for lower suspension arm using
the three-step tightening procedure:
•
•
•
Step 1 – Initial tightening: Tightening
torque 75 Nm (56 ftlb.) +/-2.5 Nm
(+/-2 ftlb.)
Securing tie rod
Step 2 – Loosening process: Torque
angle 180°
Step 3 – Final tightening: Tightening torque 75 Nm (56 ftlb.) +/-2.5 Nm
(+/-2 ftlb.)
Lower trailing arm on wheel carrier
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Information
Seal the threaded joint as shown in with
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TSB/Document ID: 122-L5R7Q-05
Replacement Service Bulletin Number:
MFR Communication Date: 2015-03-18
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SUSPENSION:MULTIPLE AXLE
MFR Component System:
MFR Component Subsystem:
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