Symptom-based workshop manual

Service
206/20 ENU

3965

3

Transmission Symptom - Oil Leakage on Transfer Box: Observe Specified Procedure (SY
206/20)
Change overview:
Release

Date

Change

0

03/01/2021

•

First publication

1

06/27/2024

•
•

Vehicle types added
“Required parts” sections adapted to new vehicle types

Model Line:

Cayenne (9YA / 9YB)

Model Year:

As of 2018

Concerns:

Transfer gear

Symptom:

Oil leakage is found on the vehicle in the area of the hang-on transfer box and at the transition to the
automatic transmission.

Cause:

We have discovered that the location and cause could not always be clearly determined in the dealer
organization when attempting to resolve the complaint “Oil leakage”. As a result, some of the repair
measures that were carried out were not always effective.
Oil migration in the area of the automatic transmission and transfer box can result in incorrect diagnoses
when locating oil leakage. For example, the radial shaft seal on the automatic transmission or transfer
box side may leak at the connection point of the automatic transmission and transfer box.
In addition, oil leakage in the area of the automatic transmission can result in escaping oil contaminating
the transfer box, due to the air flow at the vehicle underbody.
Information
In the case of oil leaks in the area of the transfer box, see also  Technical Information 'Transmission
symptom - Oil leaks on automatic transmission: Observe specified procedure (SY 205/20)'.

Remedial
action:

Find oil leakage and carry out the relevant repair measure.

AfterSales

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Symptom-based workshop manual

ENU 206/20

3965

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 PCSS line.

3

Clean automatic transmission and transfer box thoroughly.

4

Spray large areas of the automatic transmission and transfer box with SpotCheck around the
suspected leakage points.

5

Perform a test drive.

6

Locate the oil leakage:
•
•

•

The oil leakage is located on the transfer box, continue with  Technical Information 'Transmission symptom - Oil leakage on transfer box'.
The oil leakage is located on the automatic transmission, continue with  Technical Information
'Transmission symptom - Oil leakage on automatic transmission: Observe specified procedure
(SY 205/20)'.
The oil leakage cannot be clearly identified, continue with  Technical Information 'Oil leakage
on transfer box'.

7

Produce photo documentation of the leakage point located using SpotCheck.

8

Attach documentation to PCSS line.

Oil leaks on the transfer box
Information
Either the radial shaft seal on the automatic transmission or the transfer box may be damaged at the transition from automatic transmission to transfer box.

Information
Oil penetration of the connection point on the transfer box housing (housing cover) can result in incorrect
interpretations.

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AfterSales

Symptom-based workshop manual

Service
206/20 ENU

3965

3

Check for oil leaks in the area of the input shaft for hang-on transfer box  Oil migration and  Oil leak on
input-shaft radial shaft.
1

Oil leak on transfer box housing with drops forming in the area of the input shaft. The upswinging
motion of the input shaft in the axial direction causes the transmission oil ahead of the radial shaft
seal to surge with strong pressure fluctuations. This can result in an oil leak complaint.
1.1

In the event of a complain, first check the technical status of the transfer box using the differentiation table:
Differentiation of measures via hang-on serial numbers
Start of
production as of:

Part number:

Description of
change:

Start of
production VIN:

All vehicles
as of hang-on
serial number *
265 NVG0023783F

0F2341011F

Swirl-free input shaft
through modified
partly automated
grinding process

WP1AA29Y9KDA05
830
Part No.
transfer gear:
265 NVG0023783F

Start of
production:
12.04.2018
•

If the serial number on the transfer box corresponds to the specified differentiation data
from the table, the entire transfer box must be replaced, see  Technical Information
'Replacing transfer box'. Replacing the radial shaft seal alone would not be effective in
the long term and the radial shaft seal would leak again.

•

However, if the serial number corresponds to a newer version than that in the differentiation list, only the radial shaft seal may then be replaced, see  Technical Information
'Replacing sealing ring for transfer box (front transmission side)'. The hardware version
of the transfer box corresponds to the latest technical status.

Information
If the repair history of the vehicle indicates that the radial shaft seal was already replaced in
the past, a PRMS ticket must be created before carrying out repairs in order to coordinate
the relevant repair with Technical Support.
1.2

If the radial shaft seal on the automatic transmission is damaged, see  Technical Information 'Complaint - Oil leaks on automatic transmission: Observe specified procedure
(205/20)'.

AfterSales

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ENU 206/20

3965

Symptom-based workshop manual

Oil migration

Oil leak on input-shaft radial shaft
2

Oil leaks in the area of the output shaft to the rear axle  Oil leak on output-shaft radial shaft seal.
If the output-shaft radial shaft seal is damaged, see  Technical Information 'Replacing sealing ring
for transfer box (rear transmission side)'.

Oil leak on output-shaft radial shaft seal

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AfterSales

Symptom-based workshop manual

Service
206/20 ENU

3965

3

Replacing transfer box
Work Procedure: 1

For Cayenne vehicles from model year 2018 to 2019, check the permissible transfer case /
automatic transmission combinations.
See TI 22/19:  Technical Information 'Spare parts requirements for (hang-on) transfer
box/automatic transmission: Observe permitted combinations (22/19)'
Information
For Cayenne (9Yx) vehicles from other model years, TI 22/19 must be selected using Manual Series
Selection with a 2018 or 2019 model year Cayenne (9Yx) vehicle, if required.

Parts Info:

2

Replace transfer box, see  Workshop Manual '396519 Removing and installing transfer box'.

3

Check and top up oil for transfer box, see  Workshop Manual '399035 Checking and topping up oil
for transfer box'.

Required parts:
Part No.

Designation
– Point of use

Number

0F2341x 1)

 Transfer gear

1 piece

N 91239302

 12-point flange bolt
– Input shaft

6 pieces

PAF107722

 Hose clamp 36.1 x 9 x 0.6
– Cardan shaft

1 piece

or
PAF10848901

 Hose clamp 40 x 9 x 0.9
– Cardan shaft

1 piece

PAF107599

 Cheese head bolt with multiple-tooth head
– Rear cardan shaft

6 pieces

95534919121

 Plate
– Rear cardan shaft

3 pieces

PAF91203204

 Round head screw
– Protective plate / vibration damper transfer case

5 pieces

PAF00072900

 M8 x 20 hexagon socket head bolt
– Front section of front underbody cover

3 pieces

or
95530111501

 Screw plug
– Check and top up oil for transfer gear

AfterSales

1 piece

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Service
3965

Symptom-based workshop manual

ENU 206/20

N 105184052)

 Cheese head bolt with multiple-tooth head
– Universal joint

1 piece

1) Part number varies depending on transmission type
2) Only for vehicles with particle filter

Additional parts required (R4 in-line engine PHEV):
Part No.

Designation
– Point of use

Number

PAB25311500

 Seal
– Primary catalytic converter

1 piece

or
PAB253115D

 Seal
– Particle filter

1 piece

PAF911308

 Hexagon collar nut, self-locking
– Primary catalytic converter

3 pieces

PAB111220A

 Clamping sleeve
– Primary catalytic converter/particle filter

1 piece

Additional parts required (V6 monoturbo):
Part No.

Designation
– Point of use

Number

PAB25311520

 Seal
– Primary catalytic converter

1 piece

or
PAB253115D

 Seal
– Particle filter

2 pieces

or
PAB253725A

 Clamp
– Particle filter

2 pieces

PAF911308

 Hexagon collar nut, self-locking
– Primary catalytic converter

3 pieces

or
PAF911308

 Hexagon collar nut, self-locking
– Particle filter
or

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AfterSales

6 pieces

Symptom-based workshop manual

Service
206/20 ENU

3965

3

PAB253115B

 Seal
– Particle filter

2 pieces

PAB25314120

 Clamping sleeve
– Primary catalytic converter

1 piece

or
PAB111220A

 Clamping sleeve
– Particle filter

2 pieces

Additional parts required (V6 and V8 biturbo):
Part No.