996 tiptronic torque converter install

[dhamilto]

Gents, a question please for those guys that have done it: what is the install procedure for the 996 3.4l torque converter (TC)?

FYI, when I removed the tip gearbox/transmission, I left the TC on my old seized engine (had to ). The tip box came off cleanly; the outer seal looks good/new. A replacement TC, toothed driveplate and bolts have been shipped...

Should I:

(a) attach the driveplate to the replacement engine, then bolt on the TC, then turn the engine by hand to align the two TC outer shaft slots to the tip box and push it together, then bolt up?

(b) push the TC onto the tip box, bolt the driveplate to the engine, mount the tip box / TC to the engine, turn the engine by hand hoping that the tip shaft will turn with it, align the 6 driveplate bolt holes to the TC bolt holes one at a time and tighten up via the starter motor hole? WILL THE TIP BOX TURN? I HAVE NO IDEA WHETHER IT IS IN GEAR OR NOT?

Thanks for your help!

[JFP in PA]

What I do not understand is why you didn’t pull the seized engine and trans out as a unit, then disassemble them; would have been a Hell of a lot easier…….

While I heard all the arguments about removing just the transmission and leaving the torque converter in the car, it is the exact wrong way to do it. The torque converter has an internally splined stator and turbine units that have to be engaged by jiggling the unit until the fine splines line up, and then be pushed in further and rotated until the large slot on the converter’s collar has to engage the front pump. This is “fiddly” to do with the transmission sitting on the bench, so I cannot imagine doing it with the converter first bolted to the flex plate. You would also be risking the seal on the pump housing if you accidentally loaded or pinched it trying to wiggle the transmission to get the converter to properly engage while bolted in. I would never attempt to do it this way, the probability of leaks or damage is just too big.

The correct way is to disconnect the battery, pull the starter, remove the panel behind the seat, bring the engine around until the notch for any of cylinders 4, 5, or 6 is aligned with the pin boss on the block, insert the short 9595 pin into the crank pulley, insert the long 9595 pin into the bell housing opening (if it does not want to go in, go back and check the crank is actually at on one of the correct cylinder notches). Porsche tells you to then use a special tool to hold a 6MM long Allen socket while you undo two of the six converter bolts, but it can be done without special tool 9596 if you are careful NOT TO DROP THEM (this is critical on reassembly). Then pull the long and short pins, rotate the engine 120 degrees until the notch aligns again so you can get at the other four converter bolts the same way with the pins engaged. When all the converter bolts are removed, reinstall the long pin in the bell housing to hold the converter while removing the combined trans and converter from the car, undo everything else that needs to come off (mounts, hoses, etc.). Then using a trans jack, slide the trans and converter away from the engine and lower it. Reinstallation is the reverse.

[dhamilto]

Originally Posted by JFP in PA

What I do not understand is why you didn’t pull the seized engine and trans out as a unit, then disassemble them; would have been a Hell of a lot easier…….

JFP, thanks for submitting your answer. Perhaps I was not entirely clear. I did remove the engine and transmission together. My note starts from the point where I removed the tranny from the seized engine. The engine would not turn, so I could not unbolt the TC from the driveplate. That's why I had to pull the transmission leaving the TC on the engine. I now have a replacement TC and driveplate and was asking about the install procedure. Got myself a copy of the 986 workshop manual now and have checked out about TC install on Youtube so am good to go. Didnt know about the pins though, so your reply was helpful, many thanks.

[dhamilto]

Originally Posted by JFP in PA

What I do not understand is why you didn’t pull the seized engine and trans out as a unit, then disassemble them; would have been a Hell of a lot easier…….

JFP, thanks for submitting your answer. Perhaps I was not entirely clear. I did remove the engine and transmission together. My note starts after when I split the tranny from the seized engine. The engine would not turn, so I could not unbolt the TC from the driveplate. That's why I had to pull the transmission leaving the TC on the engine. I now have a replacement TC and driveplate and was asking about the install procedure. Got myself a copy of the 986 auto transmission workshop manual now and have checked out TC install on Youtube so am good to go. Didnt know about the pins though, so your reply was helpful, many thanks.

[JFP in PA]

The pins, which Porsche sells for about $100 for the pair, are simply a 5/16 rod with a nice knob on one end. Very easy to make your own if you do not have a set.

[thompsontw]

I am in the process of pulling a tip gearbox/transmission. I understand how to pull the starter and remove the 6 bolts and how to use the short 9595 pin. I am struggling to understand how to remove the panel behind the back seat so that I can install the long 9595 pin. Can someone please send me a link to a video or pictures that show this behind-the-seat procedure? Thanks in advance for your help.