NHTSA ID Number: 10130118
Manufacturer Communication Number: 122-M3B5L-03
TSB/Document Date: 2018-03-13
Summary
Cause: Clicking noises can come from around the transfer case when manoeuvring the vehicle (or driving slowly) due to activation of the transfer case servo motor. Remedial action: Before doing any other work, the symptommust be simulated using a test procedure. (Opening the door windows can be helpful when evaluating noises). 1 Conditions for the first test procedure: ? Activate the Start/Stop function and ? deactivate all sources of noise in the vehicle (Entertainment, ventilation, etc.). ? A multi-storey car park can be useful for acoustic reverberation. ? Onastraight stretch ? fromspeeds less than 10mph (20 km/h) ? brake the vehicle to a standstill. ? The best way of finding the clicking noise is by driving slowly and then stopping the vehicle.
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3995
Noise Symptom/Jerking - Clicking Noise/Rough-Running Engine/Jerking Under Load With
Respect to Transfer Case: Programming all-wheel drive control unit/checking transfer
case (SY 84/17)
ENU
Information
Currently, a high percentage of warranty returned transfer cases are evaluated as "OK" during
testing by the supplier.
For this reason, the two previous symptom-based repair instructions are being replaced by these
symptom-based repair instructions:
1. "Eliminating noise symptoms - Re-programming control unit for all-wheel drive (Creaking noise from
around the transfer case/SY0416) – only relevant for vehicles from model year 2015 to 2016
and
2. "Eliminating symptoms - Engine: Replacing transfer case (Rough-running engine, vehicle jerks
under load/SY2516)
in Repair Group 39 - Final drive.
Information
The "transfer case" is designed as an active all-wheel drive system that is dynamically adapted to the
respective driving state.
Power transmission between the front and rear axle is controlled electronically via the "all-wheel
drive servo motor (transfer case)" and the multi-plate clutches integrated in the transfer case.
On all-wheel drive vehicles, the drive train can become strained at low speeds and when the
steering is turned sharply when "Off-road mode" is activated, depending on design.
Revision:
•
Under extreme conditions, the drive train can also become strained when "Off-road mode" is
deactivated.
•
Customers with little experience with all-wheel drive vehicles can interpret this behavior as a
fault, which in turn can result in incorrect diagnoses in the workshop.
Revision 1 — This bulletin replaces bulletin dated September 22, 2017.
The Information note under “Symptom 1”, the first bullet point was amended to read: “that were
produced from model year 2015 to model year 2016 and”
Revision 2 — This bulletin replaces bulletin dated November 2, 2017.
Under Symptom 2 — Step 2.4 was added.
Model Year:
As of 2011 up to 2017
Vehicle Type:
Cayenne (VR6 - 92A)/Cayenne S (92A)/Cayenne GTS (92A)/Cayenne Turbo (92A)/Cayenne
Turbo S (92A)/Cayenne S Diesel (V8 - 92A)
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Equipment:
With transfer case
With regard to
1:
1. All-wheel drive servo motor (transfer case) see "Symptom 1" below
Information
"Symptom 1" described below and the corresponding test procedure is relevant only for vehicles
from model year 2015 to model year 2016.
This procedure and remedial action must not be used for vehicles from model years 2011 to
2014.
Symptom 1:
Clicking noises can come from around the transfer case when driving slowly or when
manoeuvring in a parking garage.
Information
The customer complaint about a clicking noise (from the servo motor) can only occur on
vehicles:
•
that were produced from model year 2015 to model year 2016 and
•
with a software version lower than version 1010 in the all-wheel drive control unit.
Cause:
Clicking noises can come from around the transfer case when manoeuvring the vehicle (or driving slowly)
due to activation of the transfer case servo motor.
Remedial
action:
Before doing any other work, the symptom must be simulated using a test procedure.
(Opening the door windows can be helpful when evaluating noises).
1
Conditions for the first test procedure:
•
•
•
Activate the Start/Stop function and
deactivate all sources of noise in the vehicle (Entertainment, ventilation, etc.).
A multi-storey car park can be useful for acoustic reverberation.
•
•
•
•
On a straight stretch
from speeds less than 10 mph (20 km/h)
brake the vehicle to a standstill.
The best way of finding the clicking noise is by driving slowly and then stopping the vehicle.
In the event of a distinct customer complaint, the clicking noise can already be heard on a straight
stretch with partial load accelerations.
To correct the problem, re-program the all-wheel drive control unit. See "Procedure"
section below.
The measure is complete after programming the all-wheel drive control unit.
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Technical Information
With regard to
2:
84/17
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Hang-on transfer case see "Symptom 2" below
Information
"Symptom 2" described below and the corresponding test procedure is relevant for vehicles
from model year 2011 to model year 2017.
For vehicles from model year 2015, the test procedure described under "Symptom 1" must
be completed before doing any other work.
Symptom 2:
Symptoms to be checked:
•
•
•
Rough-running engine or
the vehicle vibrates or
the engine jerks under load.
Information
Generally, the vehicle can start jerking when driving in tight corners with a small radius and when Off-road
mode is activated.
This behavior is perfectly normal for all-wheel drive vehicles and is not a defect on the vehicle.
NOTICE
Driving with connectors on chassis components or control units disconnected.
•
Bearings in transfer case can be damaged.
Drive vehicle only at a maximum speed of 30 mph (50 km/h).
Do not drive vehicle in the upper load range or at full throttle.
1
Carry out the test procedure under the following conditions:
•
•
•
On a straight stretch
from speeds less than 10 mph (20 km/h)
accelerate the vehicle in the partial load range.
During this test procedure, if:
•
•
jerking can be felt, the test procedure under (below) must also be carried out in order to
determine the exact cause.
no jerking is felt, see the information below about normal vehicle behavior:
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Information
Generally, the vehicle can start jerking when driving in tight corners with a small radius and when Off-road
mode is activated.
This behavior is perfectly normal for all-wheel drive vehicles and is not a defect on the vehicle.
2
Conditions for the test procedure:
•
•
•
Activate Off-road mode in the vehicle and
drive at low speed
into a tight bend with a small radius (high steering angle).
If jerking can be felt during this test procedure, work through the following steps, depending
on which equipment is installed:
•
•
with PTV PLUS (controlled rear-differential lock) – I-no. 1Y1 continue with 2.1
without front/rear differential lock – I-no. 1Y0 continue with
Information
Generally, the vehicle can start jerking when driving in tight corners with a small radius and when
Off-road mode is activated.
This behavior is perfectly normal for all-wheel drive vehicles and is not a defect on the vehicle.
2.1
Disconnect connector on the rear-differential lock control unit, see Workshop Manual
'397519 Removing and installing control unit for rear-differential lock'.
2.2
Carry out the test procedure under the following conditions, see :
Disconnecting the connector should prevent the vehicle from jerking due to a higher
rear-differential lock locking value:
If the problem occurs, continue with .
If the problem no longer occurs, the rear final drive must be replaced, see
Workshop Manual '398819 Removing and installing all-wheel final drive' and
for model year 2011 to 2013 vehicles, the steps described in the following
campaign must also be performed: Technical Information 'WC2600 WC26 Workshop
campaign - Re-programming rear-differential lock control unit'.
2.3
3
If jerking is felt during the test procedure under step , the following test procedure must still
be carried out, see 3.1 to 3.3:
3.1
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Re-connect connector on the rear-differential lock control unit, see Workshop Manual
'397519 Removing and installing control unit for rear-differential lock'.
Disconnect connector on centre differential lock (plug connection on transfer case
servo motor).
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Connector on rear-differential lock control unit must be inserted.
3.2
Carry out the test procedure under the following conditions:
•
•
•
Activate Off-road mode in the vehicle and
drive at low speed
into a tight bend with a small radius (high steering angle).
If the problem occurs, the transfer gear or rear final drive must be ruled out as
the cause.
Avoid replacing these components.
If the problem no longer occurs, the hang-on transfer case must be replaced, see
Workshop Manual '396519 Removing and installing transfer gear'.
3.3
Re-connect connector on center differential lock.
End of action required.
Tools:
•
•
9900 - PIWIS Tester III with PIWIS Tester software version 35.800 (or higher) installed
Battery Charger/Power Supply - Suitable for AGM Type batteries, recommended current rating of
90A fixed voltage 13.5V to 14.5V.
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 90A fixed voltage 13.5V to 14.5V.
NOTICE
Control unit programming will be aborted if the Internet connection is unstable.
•
An unstable Internet connection can interrupt communication between PIWIS Tester and the vehicle
communication module (VCI). As a result, control unit programming may be aborted.
During control unit programming, always connect PIWIS Tester 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.
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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.
Work Procedure: 1
Preliminary work
Carry out general preliminary work for control unit programming as described in Workshop
Manual '9X00IN Basic instructions and procedure for control unit programming using the PIWIS
Tester - section on "Preliminary work"'.
Information
The procedure described here is based on the PIWIS Tester III software version 35.800.
The PIWIS Tester instructions take precedence and in the event of a discrepancy, these are the
instructions that must be followed.
A discrepancy may arise with later software versions for example.
2
Re-program all-wheel drive control unit.
The basic procedure for programming a control unit is described in the Workshop Manual
Workshop Manual '9X00IN Basic instructions and procedure for control unit programming using the
PIWIS Tester - section on "Programming"'
For specific information on control unit programming during this campaign, see table
below.
NOTICE
Use software update via 'programming code' described below on vehicles before model year 2015.
•
Malfunctions in the system
Use the software update via “programming code” only for model year 2015 to 2016 vehicles.
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Required PIWIS Tester software version:
35.800 (or higher)
Type of control unit programming:
Control unit programming using the "Campaign"
function in the Additional menu on the PIWIS
Tester by entering a programming code.
Programming code:
G5N7B
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Read and follow the information and instructions
on the PIWIS Tester during the guided
programming sequence.
Programming sequence:
The fault memory is first deleted during the
programming sequence. If the message appears
informing you that certain fault memory entries
could not be deleted, acknowledge the message by
pressing •>>“ and start control unit programming.
During programming, the all-wheel drive
control unit will be re-programmed and then
re-codedautomatically.
Do not interrupt programming and coding.
Once the control units have been programmed
and coded, the PIWIS Tester will prompt you to
switch the ignition off and then back on again after a
waiting time of approx. 10 seconds.
Programming time (approx):
2 minutes
Data record (Porsche part number)
programmed as part of this campaign:
0C2.927.xxx.S
Procedure in the event of error messages
appearing during the programming
sequence:
Workshop Manual '9X00IN Basic instructions and
Procedure in the event of abnormal
termination of control unit programming:
Repeat control unit programming by restarting
programming.
Following control unit programming, the Porsche
part number can be read out of the 'All-wheel drive'
control unit in the 'Extended identification'
menu using the PIWIS Tester.
procedure for control unit programming using the
PIWIS Tester - section on "Fault finding"'.
If this is not possible, restart the PIWIS Tester and
then execute control unit programming again.
3
Subsequent work
3.1
Create a Vehicle Analysis Log (VAL) and mark it with the attribute "Following repairs".
Workshop Manual '0X03IN Creating Vehicle Analysis Log (VAL)'
3.2
Carry out general subsequent work for control unit programming as described in
Workshop Manual '9X00IN Basic instructions and procedure for control unit programming
using the PIWIS Tester - section on "Subsequent work"'.
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Invoicing:
The work involved is invoiced under the labor operation:
APOS
Labor operation
39952500
Programming all-wheel drive control unit
I No.
For invoicing and documentation using PQIS, enter the following coding, depending on the customer
complaint:
a) “Creaking noise” (clicking noise):
Location (FES5)
39780
Transfer case servo motor
Damage type (SA4)
2015
creaking
b) "Rough-running engine, vehicle vibrates or engine jerks under load":
Location (FES5)
39650
Transfer case
Damage type (SA4)
1313
vibrating, shaking
References:
Workshop Manual '0X03IN Creating Vehicle Analysis Log (VAL)'
Workshop Manual '9X00IN Basic instructions and procedure for control unit programming using the
PIWIS Tester - section on "Subsequent work"'
Workshop Manual '397519 Removing and installing control unit for rear-differential lock'
Workshop Manual '396519 Removing and installing transfer gear'
Important Notice: Technical Bulletins issued by Porsche Cars North America, Inc. are intended only for use by professional automotive technicians who have attended Porsche service training
courses. They are written to inform those technicians of conditions that may occur on some Porsche vehicles, or to provide information that could assist in the proper servicing of a vehicle. Porsche special
tools may be necessary in order to perform certain operations identified in these bulletins. Use of tools and procedures other than those Porsche recommends in these bulletins may be detrimental to the
safe operation of your vehicle, and may endanger the people working on it. Properly trained Porsche technicians have the equipment, tools, safety instructions, and know-how to do the job properly and
safely. Part numbers listed in these bulletins are for reference only. The work procedures updated electronically in the Porsche PIWIS diagnostic and testing device take precedence and, in the event of a
discrepancy, the work procedures in the PIWIS Tester are the ones that must be followed.
© 2018 Porsche Cars North America, Inc.
Feb 6, 2018
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TSB/Document ID: 122-M3B5L-03
Replacement Service Bulletin Number:
MFR Communication Date: 2018-02-06
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)
MFR Component System:
MFR Component Subsystem:
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