Servicing - Automatic Transmission: Removal & Installation Porsche Cayenne I

Installation

1. Install ATF lines. Connect cable connector on oil level sensor. Connect bleeder line on all-wheel final drive. Install bolt securing ATF line to ATF thermostat, transmission, transmission bell housing and engine. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-170237-S40909033232005010700000) .
2. Install front transverse strut. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170237-S40909033232005010700000) . Install front spoiler.
3. Check ATF level. See «CHECKING FLUID LEVEL»(ref-170237-S15040370352005010700000) under LUBRICATION. Top off as necessary. Install engine guard and front wheel housing liner.

Scheme 5

Scheme 6

1. Raise and support vehicle. See «DISABLING/ENABLING ELECTRONIC LEVEL CONTROL»(ref-170237-S11218705722005011200000).
2. Remove engine guard. see scheme 2
3. Remove front cardan shaft from transfer case. see scheme 12 Remove engine carrier. See «ENGINE CARRIER (4.5L V8)»(ref-170237-S19666429752005011000000).
4. Place oil collection pan under vehicle. Remove bolt (arrow) securing ATF line to ATF thermostat. (Scheme 9)
5. Remove line. Remove bolts (1, 2 and 3) securing ATF line to engine oil pan and transmission. (Scheme 10)
6. Remove ATF line. To install, reverse removal procedure. Check ATF level. See «CHECKING FLUID LEVEL»(ref-170237-S15040370352005010700000) under LUBRICATION. Top off as necessary. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170237-S40909033232005010700000).

Scheme 7

Scheme 8

1. Raise and support vehicle. See «DISABLING/ENABLING ELECTRONIC LEVEL CONTROL»(ref-170237-S11218705722005011200000).
2. Remove engine guard. see scheme 2
3. Place oil collection pan under transmission. Remove drain plug (B). see scheme 3
4. Drain ATF. See «DRAINING & REFILLING»(ref-170237-S01640471832005010700000) under LUBRICATION.
5. Remove transmission oil pan. See «ATF OIL PAN»(ref-170237-S33618644042005011000000). Remove ATF filter bolts (arrows). (Scheme 11) Remove ATF filter.
6. To install, position NEW sealing ring (arrow) on ATF filter. (Scheme 12)
7. Insert ATF filter. Tighten ATF filter bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170237-S40909033232005010700000).
8. Place NEW seal on transmission oil pan. Check position of magnets in transmission oil pan. (Scheme 14) Position transmission oil pan to transmission, and install. Tighten transmission oil pan bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170237-S40909033232005010700000).
9. Fill transmission fluid. See «DRAINING & REFILLING»(ref-170237-S01640471832005010700000) under LUBRICATION. Install engine guard.

Scheme 9

1. Raise and support vehicle. See «DISABLING/ENABLING ELECTRONIC LEVEL CONTROL»(ref-170237-S11218705722005011200000).
2. Remove engine guard. see scheme 2 Place oil collection pan under transmission.
3. Remove drain plug (B). see scheme 3 Drain ATF. See «DRAINING & REFILLING»(ref-170237-S01640471832005010700000) under LUBRICATION.
4. Install drain plug (B) with NEW sealing ring. Tighten to 21 ft. lbs (28 N.m). Remove bolts (arrows) securing oil pan to transmission. (Scheme 13) Remove transmission oil pan.
5. Place NEW seal on transmission oil pan. Check position of magnets in transmission oil pan. (Scheme 14) Position transmission oil pan to transmission, and install. Tighten transmission oil pan bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170237-S40909033232005010700000).
6. Fill transmission fluid. See «DRAINING & REFILLING»(ref-170237-S01640471832005010700000) under LUBRICATION. Install engine guard.

Removal & Installation

1. Raise and support vehicle. See «DISABLING/ENABLING ELECTRONIC LEVEL CONTROL»(ref-170237-S11218705722005011200000).
2. Remove engine guard. see scheme 2
3. On models equipped with V8 Bi-Turbo engine, disconnect connection on charge air cooler, by removing locking clip (1). see scheme 7 Pull off line. Disconnect lead of ambient air valve module (2), by removing spring band clamp.
4. Pull off line. Disconnect suction line from engine, by removing locking clip (arrow). see scheme 8 Pull off line.
5. On all models, place oil collection pan under vehicle. Undo ATF line screw connection on cooler side (arrow) at thermostat. see scheme 9
6. Remove bolt (arrow) securing ATF line to thermostat. (Scheme 9)
7. Remove bolt (arrow) securing ATF thermostat to cooler. see scheme 10
8. To prevent distribution of oil in area of front of vehicle, a discharge chute should be hold in position. Hold shop-made tool discharge chute under ATF thermostat. see scheme 11 Drain ATF from ATF cooler. Remove thermostat.
9. To install, replace sealing rings on ATF lines, and coat with ATF. Connect transmission-side ATF line to thermostat. Insert upper line first. Insert ATF cooler lines. Tighten bolt securing ATF thermostat to cooler. Tighten bolt securing ATF line to thermostat. See «TORQUE SPECIFICATIONS»(ref-170237-S40909033232005010700000).
10. Tighten ATF line screw connection on cooler side (arrow) at thermostat. see scheme 9 Counter while tighten ATF lines.
11. Connect suction line to engine, by inserting locking clip. Push line on until it engages. Connect lead of ambient air valve module, by fitting spring band clamp, and connect lead. Insert locking clip on charge air cooler suction line. Push line on until it engages.
12. Remove oil inspection plug, and fill ATF until a constant discharge is visible at lifting tube. Check ATF level. See «CHECKING FLUID LEVEL»(ref-170237-S15040370352005010700000) under LUBRICATION. Top off as necessary. Install engine guard.

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

1. Raise and support vehicle. See «DISABLING/ENABLING ELECTRONIC LEVEL CONTROL»(ref-170237-S11218705722005011200000).
2. Remove front cardan shaft front transfer box. see scheme 12
3. Support transfer box with transmission jack. Using socket insert wrench (T10204), remove collar nut of output flange. (Scheme 15) Block flange with special tool arm bracket (3435).
4. Using a shop-made tool, with striker (VW 771/1), remove output flange. see scheme 40
5. Using a seal puller (VW 681), remove sealing ring. see scheme 41 Do not damage sealing ring seat, or it will cause leaks.
6. To install, using a pressure piece (T10185), drive in NEW sealing ring until special tool touches transmission housing. (Scheme 16) Install output flange, and if necessary drive in with plastic hammer.
7. Ensure rubber ring (arrow) is inserted. (Scheme 17) Using special tool socket insert wrench (T10204), install NEW collar nut for output flange. Secure with special tool arm bracket (3435). Tighten output flange collar nut to specification. See «TORQUE SPECIFICATIONS»(ref-170237-S40909033232005010700000).
8. Caulk nuts at recesses (arrows) in output shaft. see scheme 44 Install front cardan shaft. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170237-S40909033232005010700000).

Removal

To remove lock mount, refer to illustrations. see scheme 48and (Scheme 18).

Scheme 16

Scheme 17

To install and secure lock mount, refer to illustrations. (Scheme 24)- (Scheme 29).

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

1. Raise and support vehicle. See «DISABLING/ENABLING ELECTRONIC LEVEL CONTROL»(ref-170237-S11218705722005011200000).
2. Move selector lever to position "N". Remove engine guard. see scheme 2
3. Using a second technician, with brake applied, remove cardan shaft bolts (arrow) to front of transfer box. see scheme 12 Remove transmission cross members, by supporting transmission with transmission jack, and secure with fixing strap.
4. Remove four bolts from exhaust system on cross member (center arrows). see scheme 13
5. Remove bolts (A) from support to body. see scheme 14 Remove two transmission cross member bolts (B) on transfer box holder.
6. Remove shield on transmission, by removing three bolts (arrows). see scheme 15 Pull out cable on multi-function switch.
7. Remove cap nut, cap, nut with tab washer, and rubber washer on multi-funtion switch. see scheme 16
8. Remove multi-function switch fastening bolts (arrows). see scheme 17 Position special adjustment tool (T10173) on shaft. see scheme 18 Fix to shaft with screw (arrow).
9. Install multi-function switch. Tighten bolts to 44 INCH Lbs. (5 N.m). Install cap nut, cap, nut with tab washer and rubber washer on multi-function switch. Tighten nut with tab washer to 62 INCH lbs. (7 N.m). Tighten cap nut to 132 INCH lbs. (15 N.m). Connect compact connector to multi-function switch.
10. Install shield on transmission. When installing shield, ensure that all fastening parts exist, and are inserted correctly. see scheme 19 Install three fastening bolts.
11. Install transmission cross member, by installing two bolts (B) on transfer box holder. see scheme 14 Install bolts (A). Install four bolts securing exhaust system to cross member. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170237-S40909033232005010700000).
12. Using a second technician, with brake applied, install bolts securing cardan shaft to transfer box. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170237-S40909033232005010700000). Install engine guard. Check functions of multi-function switch. Ensure vehicle starts, and selector lever works in all positions.

Scheme 24

Scheme 25

Scheme 26

1. Place selector lever in position "D". Button (inset) at front must NOT be pressed down, when selector knob is pulled. (Scheme 30) Pull selector knob up and off.
2. To install, ensure selector lever is in position "D". Spring in selector knob is overstretched. Only move selector knob as far forward, until tool can be inserted. Avoid any further overstretching. The unlocking hook in selector knob must retract to button (Gray object). (Scheme 31) Lock hook under button, using a short screwdriver (A) for example.
3. Push on selector knob until it audibly engages in selector support. (Scheme 32) Sleeve is then inserted in selector lever cover. Remove tool on handle. Check functions of selector lever cable. Ensure vehicle starts, and selector lever works in all positions.

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

1. Move selector lever to position "D". Remove selector knob. See «SELECTOR KNOB»(ref-170237-S27199516132005010700000).
2. Remove selector support. See «SELECTOR SUPPORT»(ref-170237-S23892691432005010700000).
3. Raise and support vehicle. See «DISABLING/ENABLING ELECTRONIC LEVEL CONTROL»(ref-170237-S11218705722005011200000).
4. Remove engine guard. see scheme 2 Remove shield on transmission, by removing three bolts (arrows). (Scheme 33)
5. Remove tab washer (A) on cable. (Scheme 34)
6. Unscrew selector lever cable from ball head, using removal tool (universal 21). (Scheme 35)
7. When a NEW selector lever cable is used, this should be connected directly to old cable when it is removed. This ensure that it is routed correctly. Pull selector lever cable up and out through lower part of selector support.
8. To install, route selector lever cable through lower part of selector support. Press rubber sleeve on selector lever cable into lower part of selector support. Attach tab washer (A) to cable holder on transmission side. (Scheme 34)
9. Attach cable to ball head. Cable adjustment must be changed when a NEW selector lever cable is used. Remove pins (direction of arrow), and take out cable adjustment. (Scheme 36) Insert NEW cable adjustment on selector support. Install pins in direction of arrow. (Scheme 37)
10. Ensure opening for adjusting screw (arrow) is turned upwards. (Scheme 38) Push selector onto cable adjustment. Position screw (right arrow). see scheme 22 Install tab washer (left arrow).
11. Check adjustment of selector lever cable. See «SELECTOR LEVER CABLE»(ref-170237-S28265606972005010700000) under ADJUSTMENTS.
12. Install selector support and selector knob. Check functions of selector lever cable. Ensure vehicle starts, and selector lever works in all positions. Install heat shield on transmission. Install engine guard.

Scheme 33

Scheme 34

Scheme 35

1. Raise and support vehicle. See «DISABLING/ENABLING ELECTRONIC LEVEL CONTROL»(ref-170237-S11218705722005011200000). Move selector lever to position "N". Remove engine guard. see scheme 2
2. Remove bolts (arrows) securing heat shield to transmission. (Scheme 33) Remove tab washer (A) on cable. (Scheme 34)
3. Unscrew selector lever cable from ball head, using removal tool (universal 21). (Scheme 35)
4. Using a scriber (or equivalent), push into sealing ring, and pull out (arrows). (Scheme 39)
5. To install, position NEW sealing ring (arrow). (Scheme 40) Using pressure sleeve (T10174, arrow), drive in sealing ring. (Scheme 41) Position selector lever on selector shaft. Tighten fastening nut to 132 INCH lbs. (15 N.m).
6. Attach tab washer to cable holder on transmission side. Press cable on ball joint. When installing shield ensure that all fastening parts exist, and inserted correctly. see scheme 19 Install shield to transmission. Install engine guard. Check functions of selector lever cable. Ensure vehicle starts, and selector lever works in all positions. Install heat shield on transmission.

Scheme 36

Scheme 37

1. Raise and support vehicle. See «DISABLING/ENABLING ELECTRONIC LEVEL CONTROL»(ref-170237-S11218705722005011200000).
2. Move selector lever to position "N". Remove engine guard. see scheme 2 Remove bolts (arrows) securing heat shield on transmission. (Scheme 33)
3. Remove multi-function switch. See «MULTI-FUNCTION SWITCH»(ref-170237-S13121417162005010700000). Using a scriber (or equivalent), remove sealing ring. (Scheme 42)
4. To install, using pressure piece (T10174) press NEW sealing ring as far as pressure piece system on transmission housing. (Scheme 43)
5. Install multi-function switch. Adjust multi-function switch. See «MULTI-FUNCTION SWITCH»(ref-170237-S30492854372005011000000) under ADJUSTMENTS. Install engine guard. Check functions of selector lever cable. Ensure vehicle starts, and selector lever works in all positions. Install heat shield on transmission.

Scheme 38

Scheme 39

Scheme 40

1. Remove center console cover. To remove, unscrew two screws (arrows on right), and disconnect plug connection (inset). see scheme 20 Tip cover up and back (curved arrow) and remove. Remove selector knob. See «SELECTOR KNOB»(ref-170237-S27199516132005010700000).
2. Remove selector lever cover using special tool (unlocking hook 9713). Insert hook into left and right of unlocking bracket (inset) from front. (Scheme 44) Press outward. Pull cover upward slightly at same time.
3. Remove selector lever cover, and separate cable connection. (Scheme 45)
4. Pull off electrical plug connections (arrow). (Scheme 46) Remove transverse strut of center console (arrows). (Scheme 47)
5. Unscrew selector frame screws (arrows). see scheme 21 Unscrew cable fastening screw (right arrow) on cable adjustment, using special tool, special inserts (model AB 170). see scheme 22 Remove retaining clip (left arrow). Remove selector frame.

Note. When NEW selector support is used, cable adjustment of selector cable must be modified.

Scheme 41

1. Remove pins (direction of arrow), and take out cable adjustment. (Scheme 36) Insert NEW cable adjustment on selector support. Install pins in direction of arrow. (Scheme 37)
2. Ensure opening for adjusting screw (arrow) is turned upwards. (Scheme 38) Push selector onto cable adjustment.
3. Using special tool, with special inserts (model AB 170), and accessory for torque wrench, open ring wrench insert a/f 13 with adapter 98-1, screw in selector lever cable screw connections on selector support (right arrow). see scheme 22 Tighten to 89 INCH lbs. (10 N.m).
4. Install selector frame. Tighten bolts to 53 INCH lbs. (6 N.m). Install transverse strut of center console. Position electrical plug connections on selector frame. Position cable connection on underside of selector lever cover.
5. Install selector lever cover. Ensure that wiring harness (arrow) is not pinched in selector support. (Scheme 48) Connect cable connection on underside of center console cover.
6. Insert center console cover at front and tip backward. Install two screws. Install selector knob.

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

1. Raise and support vehicle. See «DISABLING/ENABLING ELECTRONIC LEVEL CONTROL»(ref-170237-S11218705722005011200000).
2. Remove transmission oil pan and filter. See «ATF FILTER»(ref-170237-S38831959602005010700000).
3. Remove fastening screw from both connectors (arrow). (Scheme 49) Remove connectors from solenoid valves (arrows). (Scheme 50)
4. Pull off shift solenoids plugs (1, 5 and 13). see scheme 82 Remove wire harness for solenoid valves through opening in housing. see scheme 83
5. Remove connector for input shaft inductive pickup (arrow). see scheme 84 Pull off oil pressure switch plugs (3 and 4). see scheme 82
6. Remove bolt securing ATF temperature sensor (arrow). see scheme 85 Remove ATF temperature sensor. Pull off output shaft speed inductive pickup plugs (2). see scheme 82
7. Remove wire harness for sensors through opening in housing. Remove output shaft speed inductive pickup plugs (arrow). see scheme 86
8. Remove valve body. See «VALVE BODY»(ref-170237-S40109905712005010700000). Remove output shaft speed inductive pickup, by removing fastening screw (arrow). see scheme 87

1. Install output shaft speed inductive pickup. Tighten bolt to 89 INCH lbs. (10 N.m). Install valve body.See «VALVE BODY»(ref-170237-S40109905712005010700000). Connect output shaft speed inductive pickup connector.
2. Install sensor wire harness through opening in housing. Install ATF temperature sensor. see scheme 85 Tighten fastening screw to 89 INCH lbs. (10 N.m). Connect oil pressure switch connectors. Connect input shaft inductive pickup connectors. Install solenoid valve wire harness connectors.
3. Install fastening screw for both connectors. Tighten to 89 INCH lbs. (10 N.m).
4. Install ATF filter and transmission oil pan. See «ATF FILTER»(ref-170237-S38831959602005010700000).
5. Remove oil inspection plug (A) and fill ATF until a constant discharge is visible at lifting tube. see scheme 3 Install oil inspection plug with NEW sealing ring. Tighten to 52 ft. lbs. (70 N.m).
6. Check ATF level. See «CHECKING FLUID LEVEL»(ref-170237-S15040370352005010700000) under LUBRICATION. Top off as necessary.

Scheme 50

1. Raise and support vehicle. See «DISABLING/ENABLING ELECTRONIC LEVEL CONTROL»(ref-170237-S11218705722005011200000).
2. Remove transmission oil pan and filter. See «ATF FILTER»(ref-170237-S38831959602005010700000).
3. Remove transmission wiring harness. See «TRANSMISSION WIRING HARNESS»(ref-170237-S26386752042005010700000).
4. Remove bolts securing valve body (arrows). see scheme 88 Remove valve body.
5. To install, place valve body into transmission. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-170237-S40909033232005010700000). Install wiring harness, ATF filter and transmission oil pan.
6. Remove oil inspection plug (A) and fill ATF until a constant discharge is visible at lifting tube. see scheme 3 Install oil inspection plug with NEW sealing ring. Tighten to 52 ft. lbs. (70 N.m). Check ATF level. See «CHECKING FLUID LEVEL»(ref-170237-S15040370352005010700000) under LUBRICATION. Top off as necessary.