Hi guys
My '06 CTTS with 220K miles started making a terrible noise from underneath, varying with road speed, not RPM. Dropped it off at the local shop and they advise the transfer case is the culprit.
It doesn't look like new cases are available from Porsche (and are cost-prohibitive), and their normal supplier for a rebuilt case is also out of stock.

So, basically I need to source my own transfer case for them to install.

The only things I'm seeing that would work are on eBay - several used cases, and a few that are rebuilt in China (user machparts2024)

Anyone have experience or recommendations? A used case with low miles would be great, although that is hard to verify. I'm tempted to get the rebuilt case from China, although that is a bit scary.

Thanks
pf

 

Hey there PF

I just went through a similar ordeal. First before you swap it I would have your mechanic change the TC fluid which may fix your issue. If not do what I did....

1) go to https://car-part.com/ and put in your vehicle. it sorts them by miles away from you with attributes like cost and other things. (by the looks there is one with 120k miles for $156 about 200 miles away from your city)
2) For the ones that don't show how many miles on the vehicle give the shops a call and ask for the vin number of the vehicle it came out of. Then go to https://www.carfax.com/value/ and enter the vin number and you'll get last known milage


I literally did a day trip and picked one up in a neighboring state for $300 and said f-it and installed it myself. Its pretty easy and relatively straight forward. you just need some very basic tools and a half day.

Best of luck mate!

 

What a great and helpful post!

 

Yes, great post VegasCayenne. I already used your Carfax tip to rule out a case with over 200K miles.
That's also a great site to find used parts - unfortunately the unit in San Antonio seems a little dodgy.
I probably should have changed the fluid myself before taking it in - according to my records, I changed it at 185K.

When I think about how much torque this unit handles, maybe 19 years and 220K miles was a good run, I think I'd feel better with a rebuilt unit with a new chain. However, that means ordering from overseas. I'll let you guys know how that goes in a few weeks!
pf

 

Is there a article somewhere providing info on replacing the transfer case. I know the drive shaft bolts require a odd triple square tool, odd but available, fairly easy to find.

I replaced the transfer case on my BMW X3, but the Cayenne case looks much heavier. I assume this one would require a transmission jack or something, the BMW case was 60 pounds, I just lifted it into place. Wasn't easy but just doable.

 

No article that I could find and i honestly guestimated torque specs based on other VAG similar parts. If I had to do it again this is how I would do it.

Removal:
1) Unplug electronics but heat up the clips as not to break them, take your time.
2) Remove front drive shaft (DS) bolts and split it.
3) remove rear DS bolts that connect to the dapner (6 total)
4) Undo the brace that holds the rear DS to the body and split the DS from the TC. (Note: i had to pry the dapner and peal it over the metal ear of the Transfer Case and then i can pry it off. This will also give you more neck room to look at the bolts you will need to remove.)
5) remove your transfer case (TC) motor and set aside (less weight and likelyhood of getting damaged)
6) Remove all 6 of the 8 bolts that hold the TC to the transmission. The ones that you can see anyway.
7) Undo the exhaust hanger from the TC cross member and go ahead and undo the 4 cross member bolts and drop that biddi down. (you will now have to support the TC with a jack and keep a jack stand handy to transfer the weitght later on)
8) Using the jack bring the weight down as far as it goes and remove the remaining bolts.
9) Split it and start wiggling it back. Don't be afraid to give it hell! It literally has like 3" spline and it feels like forever before it comes out.

ITS OUT!

Reinstall: (I did it by myself and i'm not a big guy)
1) Get under there and do one of the two
a) inch it up on your stomach and chest and bench press that thing up. Its much easier this way since you can see the spline and guide it perfectly in. (DANGER: go for gold and don't puss out becasue you want to get it in at least 1cm in. If not you're going to be extremely scared of it landing on you)
b) Set the flat part on a traditional jack and jack it up. The problem is that the weight will transfer to where the geras are and it will want to roll up on the jack. Once it is no longer on the puck that jacks it up you really should reset and start again.
2) Once in put the jack to the back at e leve of it and jack it up leveled and give it hell pushing and wiggling it.
The worst is over
3) Reconnect everything in whatever order you see fit with the cross member being last.

 

So you just bench pressed that thing back in place, I did that with the BMW unit, but the Porsche unit looks much heavier.

Anybody know what this transfer case actually weighs?

 

No idea but I was able to man and i'm not a big guy. It was scary as all hell I'll tell you that.

However, I did manage to get it up with the jack the first time. I put a jack stand at the back wher eit meets the rear drive shaft to take a picture for my buddy. When I went back in I jacked it up a bit but the angle of the wheels was lateral and essentially moved it like 1cm back and it fell of the spline. I swear i tried to re create it like a dozen times and gave up. Finally I said screw it and benched it up.

You got this man!

 

Anyone know what happened to Parts Society (also sold on eBay under qualityporscheparts)? They were a Porsche dismantler located in New Mexico, and my favorite go-to for used parts.
Their website and eBay auctions always had a bunch of detailed photos along with a tag stating the model, year, mileage and VIN of the vehicle the part came off of. Parts had a warranty and their prices were more than reasonable.

Last thing I bought from them was a front differential in 2023. It arrived in 4 days attached to a mini pallet and layer after layer of packaging. Total was $170 including their free shipping.
You could buy TCs all day long from them for $300 to $400...they seemed to have an endless supply of Cayenne parts.

Unfortunately, their website is now 404 and it looks like their eBay store has been dormant for about a year. I was hoping they changed names, but haven't found anything like them.

 

Great advice. Car-part has been really helpful for me to find parts.

 

Follow-up - the rebuilt transfer case arrived from overseas. My local shop installed it and I have 100 miles on it. So far, so good.

I took the old case home, I've heard the rebuild is mainly a chain, thought I might give it a try sometime if this ever happens again.
The case is heavy and awkward, but a young healthy man with motivation could install it. Myself, I had enough trouble getting it out of the hatch!

 

Glad she's back on the road man!

 

Have you got any more info/ link to the 'overseas rebuild'.

Thx

 

Sure, I got it on eBay from seller "machparts2024"
I was pretty nervous waiting on it, but a little over $1300 shipped for a rebuilt one was too good a deal to pass up. At least I hope so, will feel better after another 100K miles

 

I just did mine on an 08 Cayenne. I bought a rebuilt from Transmart in California and it worked great. The case weighs 121 lbs and I had to use a low profile transmission jack.