NHTSA ID Number: 10251204
Manufacturer Communication Number: No. 163-20
TSB/Document Date: 2024-03-05
Summary
Technical information for a complaint - oil leaks on double clutch transmission
Service
Technical Information
163/20 ENU
3734
3
Complaint - Oil Leaks on Double Clutch Transmission (Porsche
Doppelkupplung (PDK)):
Observe Specified Procedure (163/20)
Change overview:
Version
Date
Change
0
04/05/2021
First publication
1
05/26/2023
•
•
•
•
•
2
02/16/2024
Order types added.
General information added.
Leaks on left side of transmission: Graphics for position 1
added.
Leaks on right side of transmission: Graphics for position
1 added.
Leaks on lower side of transmission: Information
and diagram added on how to proceed in the event of a
complaint.
Information on PDK oil pan added
Model Line:
Panamera (971)
Model Year:
As of 2017
Concerns:
Double clutch transmission (PDK)
Cause:
Information
It was established that the location and cause of oil leakage could not be clearly determined in some
cases.
As a result, some measures were not always effective.
For example, ATF pans are being replaced more frequently, although these are not the cause of the oil
loss.
Oil leaks on double clutch transmission.
Action:
Find oil leaks and carry out the relevant repair measure.
AfterSales
Feb 16, 2024
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Service
Technical Information
ENU 163/20
3734
Information
In the complaint “Oil leakages on the Porsche Doppelkupplung (PDK)”, the ATF oil pan is often incorrectly
diagnosed as a component causing damage. Component analyses have shown that the contested ATF oil
pans have no defect and were wrongly replaced. Replacing the ATF oil pan is only justified if documentation is correct. A faulty exchange will result in the warranty claim being charged back. Observe the
general warranty guidelines and the documentation guidelines.
Content:
•
•
•
•
•
•
•
Preparatory work, see Technical Information 'Preparatory work'
Leaks on left side of transmission Technical Information 'Leaks on left side of transmission'
Leaks on right side of transmission Technical Information 'Leaks on right side of transmission'
Leaks on upper side of transmission Technical Information 'Leaks on upper side of transmission'
Leaks on lower side of transmission Technical Information 'Leaks on lower side of transmission'
Leaks on front side of transmission Technical Information 'Leaks on front side of transmission'
Leaks on rear side of transmission Technical Information 'Leaks on rear side of transmission'
Preparatory work
Work
Procedure:
Information
•
Oil leaks must be clearly identifiable and reproducible.
•
Engine oil and coolant must have reached operating temperature during a test drive.
1
Document the original complaint condition with meaningful photos.
2
Attach documentation to PQIS line.
3
Clean the transmission thoroughly.
Information
In the event of a complaint regarding oil leakages, the PDK must be thoroughly cleaned, including the
transition between the oil pan and transmission, using a suitable cleaning agent. Then both the transmission and the oil pan have to be blown off with compressed air and dried before leakage detection
spray is applied to the suspected leakage point.
Feb 16, 2024
Page 2 of 47
4
Spray large areas of the transmission with SpotCheck around the suspected leakage points.
5
Test drive.
6
Check the transmission for leaks and find the leak.
7
Produce photo documentation of the leakage point located using SpotCheck.
8
Attach documentation to PQIS line.
AfterSales
Service
Technical Information
163/20 ENU
3734
3
Leaks on left side of transmission
Left side of transmission
Position
Leak area
Possible cause(s)
Repair measure
Sealing ring damaged:
Replace sealing ring on ATF
cooling line, see Technical
Information 'Replacing sealing
ring on ATF cooling line'.
Left side
of transmission -1-
ATF cooler connections
ATF cooler sealing ring
AfterSales
Feb 16, 2024
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3
Service
3734
Technical Information
ENU 163/20
Line corroded or crimping damaged:
ATF cooling line - corroded
Replace ATF cooling line,
see Technical Information
'Replacing ATF cooling line'.
ATF cooling line - crimping damaged
Screw loose
Check that it is installed
securely.
Sealing ring damaged
Replace double clutch
transmission, see
Technical Information
'Replacing double clutch
transmission'.
Sealing ring damaged
Replace sealing ring for
parking lock, see Technical
Information 'Replacing sealing
ring for parking lock'.
Left side
of transmission -2-
Screw plug
Left side
of transmission -3-
Feb 16, 2024
Page 4 of 47
Parking lock
AfterSales
Service
Technical Information
163/20 ENU
Check that it is installed
securely.
Sealing ring damaged
Replace double clutch
transmission, see
Technical Information
'Replacing double clutch
transmission'.
Screw plug
Screw loose
Left side
of transmission -5-
Screw plug
3
Screw loose
Left side
of transmission -4-
3734
Sealing ring damaged
Check that it is installed
securely. Replace screw plug
if necessary, see Technical
Information 'Replacing
screw plug'.
Leaks on right side of transmission
Right side of transmission
AfterSales
Feb 16, 2024
Page 5 of 47
3
Service
3734
Position
Technical Information
ENU 163/20
Oil leak
Possible cause(s)
Repair measure
Sealing ring damaged:
Output shaft sealing ring
O-rings damaged:
Replace sealing ring for front
output shaft, see Technical
Information 'Replacing sealing
ring for front output shaft'.
Right
side of
transmission -1-
Front output shaft
Output shaft O-rings
Feb 16, 2024
Page 6 of 47
Connecting shaft damaged
Check connecting shaft and
replace it if necessary, see
Technical Information
'Replacing connecting shaft'.
Cap damaged (2WD)
Replace cap at transmission
output, see Technical
Information 'Replacing cap
at transmission output'.
AfterSales
Service
Technical Information
163/20 ENU
Check that it is installed
securely.
Seal damaged
Replace double clutch
transmission, see
Technical Information
'Replacing double clutch
transmission'.
Screw loose
Check that it is installed
securely.
Seal damaged
Replace double clutch
transmission, see
Technical Information
'Replacing double clutch
transmission'.
Screw loose
Check that it is installed
securely.
Seal damaged
Replace double clutch
transmission, see
Technical Information
'Replacing double clutch
transmission'.
Transmission housing
Right
side of
transmission -3-
Transmission housing
Right
side of
transmission -4-
Right
side of
trans-
Transmission housing
Screw plug
3
Screw loose
Right
side of
transmission -2-
3734
Screw loose
Sealing ring damaged
Check that it is installed
securely. Replace screw plug
if necessary, see Technical
Information 'Replacing
screw plug'.
mission -5-
AfterSales
Feb 16, 2024
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3
Service
3734
Technical Information
ENU 163/20
Leaks on upper side of transmission
Upper side of transmission
Position
Oil leak
Cause
Repair measure
Oil over-filled
Check and top up ATF; see
Technical Information 'Checking
and topping up ATF'.
Insufficient defoamer
Change ATF, see Technical Information
'Replacing oil drain plug'.
Breather defective
Replace hydraulic chamber breather,
see Technical Information
'Replacing breather'.
Upper
side of
transmission -1-
Feb 16, 2024
Page 8 of 47
Hydraulic space bleeder
AfterSales
Service
Technical Information
163/20 ENU
3734
3
Leaks on lower side of transmission
Information
If oil has leaked into the ATF pan, proceed as follows in the event of a complaint:
•
Check that accessible screws on the ATF pan are installed securely with the specified tightening
torque and tighten them correctly if necessary.
•
Clean the ATF pan area thoroughly as oil leaking in under the ATF pan seal can lead to the wrong
conclusions.
Information
If the oil leak has spread so that the oil pan is also oily, as shown, proceed as follows in the event of a
complaint:
•
Ensure that the accessible oil pan screws are tighten to the specified torque.
•
Before carrying out any further work, the entire transmission must be thoroughly cleaned in the
areas of oil leaks/ oil contamination and sprayed with a suitable leak tracer/ spray (commercially
available).
•
Clean the transmission oil pan area extremely thoroughly. An oil pan seal leak can lead to incorrect
interpretations. Then perform a test drive.
•
After the test drive, check the transmission for oil leaks below.
ATF oil pan
AfterSales
Feb 16, 2024
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Service
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Technical Information
ENU 163/20
Lower side of transmission
Position
Oil leak
Lower
side of
transmission -1-
Oil drain plug
Lower
side of
transmission -2-
Feb 16, 2024
Page 10 of 47
Repair measure
Screw loose
Check that it is installed securely.
Replace oil drain plug if necessary,
see Technical Information
'Replacing oil drain plug'.
Sealing ring damaged
Screws loose
ATF pan
Lower
side of
transmission -3-
- 6X better wear protection on critical engine parts than...
- 1.3X better sludge protection than industry standards*
- 3X Stronger against viscosity breakdown than leading full...
- Protection for 10,000 miles between oil changes
- Meets or exceeds the following specifications: API SP/SN...
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TSB/Document ID: No. 163-20
Replacement Service Bulletin Number:
MFR Communication Date: 2024-02-16
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
MFR Component System:
MFR Component Subsystem:
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