Automatic Transmission, Controls, Case: Removal & Installation Porsche Boxster 986 рестайлинг

REMOVAL

Note. The selector cable must not be excessively bent or kinked.

Scheme 24

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Scheme 27

1. Move selector lever to "P" position.
2. Detach selector lever cable at deflection lever and at transmission support.
3. Remove selector knob. See «REMOVING AND INSTALLING SELECTOR KNOB»(ref-199506-S07149943322005101900000) .
4. Remove center console. See «REMOVING AND INSTALLING CENTRE CONSOLE»(ref-199812-S21755152312005102000000) .
5. Remove rear wall cover.
6. Remove cable holder.
7. Disengaging selector lever cable: Slide the locking sleeve of the adjuster (1) forward and turn it clockwise to removal position. Press the retaining clip (2) together and carefully pull the cable upward out of the support bracket.
8. Press out locking piece and remove selector lever cable. Take care not to soil the passenger compartment.

Scheme 28

Scheme 29

1. Route the selector lever cable (1) through the rear wall to the correct position on the transmission and fasten on the transmission. (Scheme 28)
2. Insert locking piece in the rear wall and fit rear wall cover.
3. Fasten cable on support bracket (2). (Scheme 29)
4. Fit cable holder.
5. Move selector lever and transmission to position "P".
6. Press cable into the open adjuster (1) and close the adjuster (3). The locking sleeve must move to the end position automatically.
7. Check adjustment of the selector lever cable. See «ADJUSTING SELECTOR LEVER CABLE»(ref-199506-S29886418862005101900000).

Scheme 30

1. Move selector lever and transmission selector shaft to position "P".
2. Adjust cable length at mounting head so that the cable can be fitted free of tension.
3. Check adjustment. To do this, select all gears and check that the gear is indicated in the right-hand instrument cluster. Also change gate from "D" to "M". A straight movement must be possible without catching.

INSTALLATION

1. Assemble the selector knob with spring clip, compression spring and locking button. NOTE: Fit conical compression spring with the small diameter facing the guide peg.
2. Press the complete selector knob onto the shift lever until it bottoms and check function of the locking button.

Scheme 31

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Scheme 33

1. Remove selector knob. See «REMOVING AND INSTALLING SELECTOR KNOB»(ref-199506-S07149943322005101900000).
2. Remove center console. See «REMOVING AND INSTALLING CENTRE CONSOLE»(ref-199812-S21755152312005102000000).
3. Move selector lever to position "D".
4. Disengage keylock cable: Open adjuster (3) by pressing the unlocking button (7). (Scheme 32) Press the retaining clip (4) together and carefully pull the adjuster (3) upward out of the support bracket. (Scheme 32) Disengage cable nipple (1) on the keylock lever (2). (Scheme 32)
5. Disengaging selector lever cable: Slide the locking sleeve of the adjuster forward and turn it clockwise to removal position (8). (Scheme 32) Press the retaining clip (10) together and carefully pull the cable upward out of the support bracket. (Scheme 32)
6. Disconnect plug connection.
7. Unscrew fastening nuts (11). (Scheme 32)

Install in reverse order, observing the following points

Scheme 34

1. Tighten fastening nuts (11) to 10 Nm (7.5 ft.lb). (Scheme 32)
2. Fastening selector lever cable: Press the cable into the support bracket until the retaining clip engages in the housing (10). (Scheme 32) Press cable into the open adjuster (8) and close the adjuster (9). The locking sleeve must move to the end position automatically (9). (Scheme 32)
3. Fastening keylock cable: NOTE: The keylock cable should only be adjusted when the selector lever is fitted. Install selector knob. Refer to «REMOVING AND INSTALLING SELECTOR KNOB»(ref-199506-S07149943322005101900000). Turn ignition key to position "1" (ignition on) and move selector lever to position "D". (Scheme 32) Open adjuster (3). (Scheme 32) Engage cable nipple (1) on the keylock lever (2). (Scheme 32) Press housing for adjuster (3) into the support bracket until the retaining clip (4) engages. (Scheme 32) Move selector lever to position "P" and turn ignition key to position "0" (removal position). (Scheme 32) Press cable sleeve (5) toward the selector support. (Scheme 32) Release cable and press locking button (7) until it engages. (Scheme 32)
4. Check keylock function: Turn ignition key to position "1" (ignition on). (Scheme 32) Move selector lever from position "P" to "D" and turn ignition key counter-clockwise. The removal position must not be reached. (Scheme 32) Release ignition key again and engage selector lever position "P". In this position, it must be possible to remove the ignition key and the locking button must be locked. (Scheme 32)
5. Remove selector lever again.
6. Fit rotary valve in correct position and install center console.

Scheme 35

Scheme 36

1. Remove center console. See «REMOVING AND INSTALLING CENTRE CONSOLE»(ref-199812-S21755152312005102000000) .
2. Removing and installing selector support. See «REMOVING AND INSTALLING SELECTOR SUPPORT»(ref-199506-S02633153702005101900000) .
3. Remove cover plate on selector lever support.
4. Pull off cable on manual switch, unclip holder for plug connection and remove cable from the cable guides.
5. Pull solenoid holding clip only far enough away to permit the solenoid can be removed. Do not overstretch the holding clip.

1. Fit solenoid in correct position and properly route cable underneath the cable guides (see Figure at left).
2. Plug cable onto manual switch according to wiring diagram and fasten plug connection with holder on the selector support.

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Scheme 39

1. Detach selector lever cable at deflection lever.
2. Unclip push rod on transmission lever.
3. Remove snap ring for deflection lever and remove lever with push rod.

1. Lubricate deflection lever axle and bushings with Optimoly TA (available from Porsche Parts Service).
2. Install deflection level and fit snap ring.
3. Clip in push rod and press selector lever cable onto axle of the deflection lever as far as it will go.
4. Check adjustment of the selector lever cable. See «ADJUSTING SELECTOR LEVER CABLE»(ref-199506-S29886418862005101900000) .

Defective toroidal sealing rings at inner oil tube let ATF enter the differential, which becomes overfilled, and oil emerges from the vent of the differential.

In general, a removed oil tube should be replaced.

The oil tube must be inserted only with special tool 3381. Otherwise there is a danger of leakage due to bending of the oil tube.

Scheme 40

1. Remove hydraulic control unit.
2. Lever out oil tube with a screwdriver.

Note. Always replace oil tube and toroidal sealing rings.

Scheme 41

1. Provide oil tube with new toroidal sealing rings and give rings a thin coating of Vaseline.
2. Insert oil tube into special tool 3381 and push into transmission housing as far as the stop on the special tool. The open side of the special tool should face the outer wall of the transmission.

Note. Do not tilt oil tube. Drive in both tube ends equally.

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Scheme 45

1. Hold engine by transport shackle in installed position with special tools 10 - 222A and 9591/1.
2. Remove the left catalytic converter.
3. Detach selector lever cable from deflection lever and transmission support.
4. Place transmission jack under the transmission.
5. Remove the left transmission support with hydraulic mount. NOTE: The fastening nut M12 (C) must not be loosened. The transmission support will otherwise be damaged. A Transmission support B Hydraulic mount C Fastening nut M12
6. Release and disconnect cable connection to multifunction switch.
7. Unscrew fastening screws and pull switch off the selector shaft.

Install in the reverse order.

Scheme 46

Scheme 47

1. Put multifunction switch on the selector shaft. The flat point on the serrations in the switch (3) must lie against the flat point on the selector shaft (1). NOTE: Place multifunction switch on the selector shaft. Do not tilt or use force: you may damage the switch contacts.
2. Turn switch until the fitting bore (4) can be put on the dowel pin (2) on the transmission housing. (Scheme 47)

1. Thinly coat sealing lip and circumference of sealing ring with Vaseline.
2. Drive in sealing ring with special tool 3385 as far as the mounting face.

Note. The open side faces the transmission.

Scheme 48

Scheme 49

ATF FILTER COMPONENT DESCRIPTIONS

REMOVE THE TIPTRONIC CONTROL UNIT

Note. The Tiptronic control unit is located in the rear luggage compartment on the bulkhead. The ignition key must be removed before starting the assembly work. If the Tiptronic control unit is replaced, observe the points under coding the control unit. See CODING THE TIPTRONIC CONTROL UNIT .

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Scheme 52

1. Open rear luggage compartment lid and lever out the clips for the carpet lining using the removal tool. See «TOOLS»(ref-199506-S37331360072005101900000) .
2. Fold over the carpet lining and unscrew the 3 fastening nuts for the Tiptronic control unit.
3. Lift out the control unit and open the connector -arrow- and remove.
4. Remove the control unit.

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Scheme 54

1. Connect the connector on the control unit and insert the closing bracket until it engages.
2. Position control unit and secure with the fastening nuts. Tightening torque: 10 Nm (7.5 ft.lb).
3. Fold back the carpet lining into position and fasten with the clips.
4. Program the Tiptronic control unit with the Porsche System Tester. See «CODING THE TIPTRONIC CONTROL UNIT»(ref-199506-S01248226482005101900000) .