Automatic Transmission, Controls, Case: Other Porsche Boxster 986 рестайлинг

REMOVING AND INSTALLING SELECTOR KNOB

Note. In vehicles manufactured before 21.1.1997, the selector knob is only pushed on and can be pulled off by hand. As from 22.1.1997, Porsche has been installing a new gear selection actuator as standard, in which the selector knob is fixed in installation position with a spring clip.

Scheme 57

Scheme 58

1. Lever off locking button with an angled pipe. The locking button must be pressed so that the pipe section can be inserted between the shift lever and the locking button. To do this, turn the ignition key to "1" position.
2. Remove the compression spring and spring clip and pull off the selector knob.

1. Compression spring (conical as of 12.10.98)
2. Spring clip

REMOVING AND INSTALLING TIPTRONIC TRANSMISSION

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

1. Disconnect battery. Refer to «WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY»(ref-199496-S08906116372005101900000).
2. Remove starter. Refer to «REMOVING AND INSTALLING STARTER - BOXSTER S»(ref-199496-S27007088562005101900000).
3. Remove rear wall cover in the passenger compartment.
4. Turn crankshaft to the extent that one of the U4, U5 or U6 bores in the belt pulley is aligned with the centering bore in the crankcase.
5. Insert special tool fixing pins 9595/1 (short) into the crankcase bore through the belt pulley. NOTE: This fixes a defined position for the crankshaft. If the special tool cannot be inserted, it must be checked whether the belt pulley is in the correct position in relation to the crankcase.
6. Insert special tool assembly aid 9596 into starter opening.
7. Turn converter fastening screws outwards through the openings in the special tool assembly aid 9596 -arrow- with 6-mm hexagon socket. (Scheme 61) NOTE: Steps 6 and 7 are to be repeated another 2 times. Before each repetition, the fixing pin (short) is to be removed out of the belt pulley, the crankshaft is to be turned by a further 120°C and the fixing pin is to be reinserted. All 6 converter fastening screws are to be removed in this way.
8. Push special tool fixing pins 9595/1 (long) through the opening in the transmission housing in order to secure the torque converter from falling out.
9. Pull vacuum pipe -B- off the switch-over valve.
10. Unscrew vent line off the engine transport eyebolt.
11. Secure engine to transport eyebolt with special tool support device 9591/1. NOTE: The engine is kept in the installation position with the support device 9591/1.
12. Remove the diagonal braces. Refer to «REMOVING AND INSTALLING DIAGONAL BRACE»(ref-199511-S07496556022005101900000).
13. Remove sheetmetal brace. Refer to «REMOVING AND INSTALLING SHEETMETAL BRACE»(ref-199511-S09119309322005101900000).
14. Remove stabilizer. Refer to «REMOVING AND INSTALLING REAR STABILIZER»(ref-199511-S19563229272005101900000).
15. Release rear cross member (V strut).
16. Remove rear muffler. Refer to «REMOVING AND INSTALLING REAR MUFFLER -AUTOMATIC»(ref-199495-S10829983592005101900000).
17. Remove rear cross member (V strut).
18. Remove catalytic converters. Refer to «REMOVING AND INSTALLING CATALYTIC CONVERTER»(ref-199495-S04935125432005101900000).
19. Remove rear-axle cross member. Refer to «REMOVING AND INSTALLING THE REAR-AXLE CROSS MEMBER»(ref-199511-S22075795722005101900000). NOTE: In order to protect the drive shafts, it is possible, for instance, to use a length of hose which has a diameter of 30 mm.
20. Remove drive shafts on the transmission and protect shafts from damage.
21. Disconnect coolant supply hose with special tool hose clamp 3094.
22. Disconnect coolant return hose with special tool hose clamp 3094.
23. Slacken spring-band clamps. NOTE: Collect emerging coolant in a suitable pan.
24. Pull off coolant supply and return hoses.
25. Disconnect plug connection for multifunction switch.
26. Disconnect plug of transmission socket. To do this, turn plug anticlockwise and pull off.
27. Detach selector lever cable at deflection lever and at the transmission support. -Arrows- (Scheme 69)
28. Place transmission jack under the transmission and fasten fixing strap. NOTE: The transmission support can be damaged by releasing the fastening nut -C-. Do not undo fastening nut -C-!
29. Release transmission support with left and right hydraulic mounts. To do this, turn both fastening screws outwards -arrow-. (Scheme 70)
30. Turn connecting screws between transmission support and transmission outwards and remove transmission support.
31. Unscrew the fastening screws between the transmission and engine. NOTE: When pulling the transmission out, ensure that the transmission support has already been released.
32. Pull transmission to the rear and lower it carefully.

INSTALLING TIPTRONIC TRANSMISSION

Note. Before beginning to install, ensure that the converter is still fixed in its installation position with special tool fixing pins 9595/1.

Scheme 72

1. Insert transmission carefully with transmission jack.
2. Screw in screws and tighten with stipulated tightening torque. See «TIGHTENING TORQUE SPECIFICATIONS»(ref-199506-S42779380292005101900000) . TIGHTENING TORQUE SPECIFICATIONS - TIGHTENING SCREWS BETWEEN TRANSMISSION AND ENGINE No. Screw/nut Tightening torque in Nm (ft.lb) 1 M 12 x 70 85 (63) 2 M12 x 100 (with washer) 85 (63) 3 M12 x 90 85 (63) 4 M10 x 35 (internal serration) 45 (33) 5 M10 (hexagon nut) 45 (33) 6 M 12 x 70 85 (63) 7 M 12 x 90 85 (63) NOTE: In order to install the right-hand hydraulic mount, the unit must be pushed towards the left.
3. Install right hydraulic mount. Tightening torque: 23 Nm (M8) Tightening torque: 65 Nm (M10)
4. Install left hydraulic mount. Tightening torque: 23 Nm (M8) Tightening torque: 65 Nm (M10)
5. Remove transmission jack.
6. Engage selector lever cable at deflection lever and at the transmission support.
7. Insert plug into transmission socket and turn clockwise until it reaches the locking point.
8. Insert plug for multifunction switch.
9. Push on coolant supply and return hoses and attach spring-band clamps in the correct position.
10. Remove hose clamps 3094.
11. Remove protection from drive shafts and fit drive shafts. Tightening torque: 39 Nm (29 ft.lb)
12. Install rear-axle cross member. Refer to «REMOVING AND INSTALLING THE REAR-AXLE CROSS MEMBER»(ref-199511-S22075795722005101900000) .
13. Install catalytic converters. Refer to «REMOVING AND INSTALLING CATALYTIC CONVERTER»(ref-199495-S04935125432005101900000) .
14. Insert rear cross member (V strut) and turn fastening screws by one or two rotations into the body.
15. Install rear mufflers. Refer to «REMOVING AND INSTALLING REAR MUFFLER -AUTOMATIC»(ref-199495-S10829983592005101900000) .
16. Tighten screws between rear cross member (V strut) and body. Tightening torque: 65 Nm (48 ft.lb)
17. Install stabilizer. Refer to «REMOVING AND INSTALLING REAR STABILIZER»(ref-199511-S19563229272005101900000) .
18. Install sheetmetal brace. Refer to «REMOVING AND INSTALLING SHEETMETAL BRACE»(ref-199511-S09119309322005101900000) .
19. Install diagonal braces. Refer to «REMOVING AND INSTALLING DIAGONAL BRACE»(ref-199511-S07496556022005101900000) .
20. Remove support device 9591/1.
21. Screw vent line onto engine transport eyebolt. Tightening torque: 10 Nm (7.5 ft.lb)
22. Push vacuum pipe onto switch-over valve.
23. Remove dowel pin 9595/1 (long).
24. Turn crankshaft to the extent that one of the U4, U5 or U6 bores in the belt pulley is aligned with the centering bore in the crankcase.
25. Insert special tool fixing pins 9595/1 (short) into the crankcase bore through the belt pulley.
26. Insert special tool assembly aid 9596 into starter opening.
27. Screw converter fastening screws in through the openings in the special tool assembly aid 9596. Tightening torque: 39 Nm (29 ft.lb) NOTE: Steps 26 and 27 are to be repeated another 2 times. Before each repetition, the fixing pin (short) is to be removed out of the belt pulley, the crankshaft is to be turned by a further 120°C and the fixing pin is to be reinserted. All 6 converter fastening screws are installed in this way.
28. Install rear wall cover in the passenger compartment.
29. Install starter. Refer to «REMOVING AND INSTALLING STARTER - BOXSTER S»(ref-199496-S27007088562005101900000) .
30. Connect the battery. Refer to «WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY»(ref-199496-S08906116372005101900000) .
31. Fill and bleed cooling system.
32. Perform suspension alignment. Refer to «SUSPENSION ALIGNMENT, COMPLETE»(ref-199512-S16548440342005101900000) .

REMOVING ATF FILTER

1. Drain ATF. See «CHANGING ATF FLUID»(ref-199506-S15380585362005101900000).
2. Remove ATF pan. To do so, unscrew the screws crosswise - in overview 5 - and remove ATF pan. see scheme 56
3. Remove ATF filter. To do so, unscrew the screws - in overview 9 - and pull out filter downwards. see scheme 56

Scheme 73

Scheme 74

1. Insert ATF filter and fasten with screws -arrow-. (Scheme 73) Tightening torque: 6 Nm (4.5 ft.lb) NOTE: Thinly coat gasket at suction collar with Vaseline.
2. Clean magnets - in overview 8 - and lay them in the seams of the ATF pan. Ensure contact over full area.
3. Fit ATF pan with new seal. Tighten screws - in overview 5 - in specified tightening sequence. (Scheme 74) Tightening torque: 11 Nm (8 ft.lb)
4. Fill in ATF. See «CHANGING ATF FLUID»(ref-199506-S15380585362005101900000).

CODING THE TIPTRONIC CONTROL UNIT

Note. If a new control unit is installed, the control unit must adapt first. Poor shifting quality can be expected therefore in the adaptation phase. The instructions of the Porsche System Tester have highest priority. The procedure listed has been structured generally, changes or additions can be made. The basis of this is the Tester Software 13.1.

1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch ignition on.
2. Select vehicle type using the cursor keys.
3. Using the >> key, move from the vehicle type to the list of control units.
4. Select Tiptronic with the cursor keys and press the >> key.
5. Select Coding with the cursor keys and press the >> key.
6. Select the Country coding and press the >>.
7. Select the country version and code with the F8 key. COUNTRY VERSION SELECTION Country version: RoW/USA Taiwan Korea
8. Tester confirmed: Coding has been modified, return again <<.
9. Select ABS/PSM and proceed with >>.
10. Select ABS or PSM, depending on vehicle equipment and code with F8.
11. << return and leave menu.
12. Perform test drive and check fault memory with the System Tester.

Scheme 75

SPECIAL TOOL

Poses Online