tony joseph

unfortunately no warranty, this region only two year warranty ,my car three year over,
any possibility repair distance sensor, any repair procedure available please let me know...three month car struck

PV997

Ruperto, that is awesome, great work! Million questions of course, but first off, can you tell what material seals the back of the distance sensor? Is it hard potting (epoxy) or something more pliable? Also, are those four tabs on each side of the distance sensor part of the back seal? My biggest concern is getting the distance sensor open without damaging things inside.

TomGT3

Has anyone tried an oil cooler? I get the error (gear locks) only after driving 20-30 minutes, or longer on cold days.

https://lnengineering.com/products/b...2-991-911.html

gsalmen1974

thats exactly what i did after fighting with ZF with a zero output for weeks to get that damn sparepart - they are not risking their job by breaking the zf cartell - contract while giving the part away - it is there - the produce it they use it for about 20 years as long they are in contract with their customers (porsche, bmw, etc) after that the „reparaturfreigabe“ will be given - from that on they stop the behaviour - waiting for 20 years ? the failure is in their mindset - they really told me: if you can afford a 160k for a car - you should EXPECT to have a 15k cost impact !
my commitment and joy with porsche is gone - i bought a used pdk and build it in - the old one with the p1731 is on sale for 3k !
love it change it leave it - one needs to know when the fight is over - all the best Georg

PV997

Had a chance to digest the comment and photos from Ruperto up in comment #330 and it looks like we can add some info to what we already know:

1) You must remove the covers at the end of the case that cover the driveshaft and the mainshaft. The driveshaft has a large bolt the must be removed, the mainshaft has a large nut. The AWD version will have a longer shaft with a coupling flange whereas the RWD version will have a shorter mainshaft that ends just past the end of the case. Both have the large nut but they are at different locations depending on AWD or RWD.

2) As Ruperto noted you need a puller to separate the shafts from the bearings (which are attached to the end case via a bolted flange). Looks like Ruperto pressed on the mainshaft (lower) while pulling on the end case around both the driveshaft and mainshaft.

3) There's a gasket between the cases that does not use a sealer. Using a puller helps save this gasket as prying isn't needed at the seam. Porsche does not offer this gasket so if it gets damaged you'll have to make a new one from scratch.

4) The distance sensor is held in place with three screws with torx heads. The distance sensor has a small connector at the top so the sensor can be removed without removing the harness.

5) Parking lock and pawl is implemented differently in the 997 (in the main case) vs. the 987 (in the end case) transmission. This may alter the removal/assembly procedure some depending on the car.

6) The end case can likely be pressed back on using the driveshaft bolt and mainshaft nut. Tighten both sequentially to gradually press the shafts back into the bearings simultaneously.

7) Porsche sells replacement caps and seals for the driveshaft/mainshaft if needed.


Unanswered questions:

1) What is the end case bolt torques?

2) What are the mainshaft bolt and driveshaft nut torques?

3) The bearings can be removed from the end case by removing the holding flange once separated. What are the part numbers if replacements are needed?


I'll update this comment as we learn more.

Mrhobbiest

Another 6 hour plus round trip, highway/back road tour with no codes. Wondering if the gear oil was actually overheating prematurely. And therefore cascaded the series of codes. Presently, the new oil seems to be helping, even if it's a placebo. Possible track test in Nov. Stay tuned.
Thanks for the continued PDK dissection!

Damien Law

Hi PV997,

I have a few of those sensors but broken. Do you have WhatsApp so we can communicate easily?

PV997

No Whatsapp but we'll work something out. I accepted your friend request so you should be able to PM me.

Damien Law

I can see that you have accepted my req but I am unable to Private Message you for i do not know what reason.. is it because my account is too new? or maybe you can try to PM me instead ..

PV997

Won't let me send to you either, probably a minimum number of comments needed. I PM'd the admin asking about it, I'll update this comment if I get some info.

Edit: Not sure what's the issue with PMs so I set up a new email account you can use to contact me. It's pv997 at mail dot com (mail.com not gmail). Once you email I'll reply from my regular email account. Didn't want to post that here due to spam.

PV997

Bumping this.

Not sure what's the issue with PMs so I set up a new email account you can use to contact me. It's pv997 at mail dot com (mail.com not gmail). Once you email I'll reply from my regular email account. Didn't want to post that here due to spam.

Wesley Stanek

Hey guys the high resolution photo of the open PDK was taken by me at my shop, we successfully were able to replace the sensor and repair the transmission. if anyone needs information on this repair or testing you can direct message me here, or on Instagram at "wstanek".

lates,
Wesley Stanek

PV997

Thanks Wesley, appreciate the work you have done and your willingness to tackle the PDK when so many won't. Most shops are afraid to touch the PDK so people who aren't experienced DIY'ers don't have an option. I stumbled across the photo and would be happy to add attribution and your contact info to the main post beneath the photo. Drop me an email at pv997 at mail dot com if that's okay with you.

steve0827

Hi all - been experiencing intermittent PDK emergency run errors that puts the car in neutral for the past 5.5 years (always go away immediately after cycling the car with zero issues in drivability). Over the past month, they seemed to happen more frequently. On Friday, I received 2 errors in a row and then a CEL after cycling car the 3rd time. From the limited drive back to my garage (less than a mile), the car seemed to drive fine with the CEL. Trying to find time this week to get it scanned with a PIWIS to see what the codes are. My race team owner in Atlanta has told me that he doesn't mind cracking open the trans if it comes to it.

Does anyone know if any sensors people are having trouble getting their hands are available through Porsche Motorsports? I know a lot of the club racers use 1st gen PDK, and the GT4 Clubsport has been using PDK. May be worth checking parts number against motorsports available parts?

HenryPcar

Excellent, excellent writeup ! Just shows knowledge is the fundamental basis of everything. Without it, everything becomes a mystery and fraudulent kicks in.