987.2 PDK

I’m feeling like a big dummy. My 09 Cayman S PDK has been an outstanding car. It has 165,000 very fun miles and no issues to speak of, no cel no PDK problems whatsoever. After 2-3 years of reading and research, I decided to service my PDK clutches and trans. Porsche FFL 3 and porsche 75-90. 2 quarts came out of the differential - trans, 2 went in. 3 quarts came out of the PDK clutch side, 3 went in. I got the trans emergency run upon start up. This car was running perfectly before servicing. The car hasn’t been on the road or driven, it doesn’t take gear well. I decided to sleep on it. I decided to just repeat the process, I had plenty of fluid. When I opened the fill on the diff-trans side, I got a lot of spill from the fill hole, like big overfill. I open the drain on the PDK clutch side, the pan, nothing coming out, it’s dry. What the heck. I proceed to repeat the service steps. Diff-trans side first. PDK clutch second. My wife put the car in R D P as I completed the fill on PDK clutch side. I tried to get it to take gear and it would, but trans emergency run. The next morning, I opened the drain on the PDK clutch...dry, no fluid. Again trans side is way over fill. My PDK clutch fluid is all being pumped to the trans 75-90 fluid. It’s a fact gentleman. I’m 55 years old and have years of experience. Seems impossible...it is happening. I feel like a big dummy. The car was running perfectly. I decided to just STOP. I made a service appointment with porsche of Birmingham Alabama. 6 week wait. I will absolutely post their diagnoses. Anybody here ever seen this happen ? Very very bizarre

Never heard of that before and I'm curious as to the solution. Did you look for any videos on YouTube to possibly supply you with an answer? I would be using Google and YouTube to try and figure it out while you are waiting. Sent from my SM-S908U using Tapatalk

Thank you. Yes, I read every article I could find on YouTube and internet several years in advance. I went in feeling very confident. I gotta say very very tough cars. I bought this one in 2015 with 80,000 miles and a cel emergency trans run...smoking big on start up. Replaced MAF, temporary fix. Replaced AOS ( air oil separator ) cleaned plenum and bingo, fixed. History of my ownership. Broke bolt holding tensioner pulley on belt. Fixed. Emergency trans run, new coils plugs and battery. Fixed. At 165,000, uses NO oil, changed every 5000 or so. It stays on the floor often, wide open. I also am a cancer patient and I bought the car to boost my spirits and to drive back and forth to treatments. It worked. That is why so many miles. 100 miles round trip 3 times a week. Big shout out to all who own a 987.2 cayman. Bullit proof cars in my opinion. Enjoy them. They are tough cars. If I do indeed need a trans I’m not complaining at 165,000...Indy shop I spoke with ( 2 month wait ) says he doesn’t believe it’s toast since it has not been driven and was working flawlessly before I attempted service. June 14 is my appointment with Porsche. I suppose I will flat truck it there empty of all Transmission and Clutch fluid with my tail between my legs

I would imagine since the PDK clutch oil is pumping to trans side, we are no longer thinking the 3 quart service amount. I would think it’s the 5.5 quart total, PDK pan is dry after going through the gears at a stand still. I am not a patient person. I am waiting on more PDK FFL 3 to arrive. I plan to open the drain on trans diff side, it is empty. As I put in the FFL 3, curious to see if it immediately drains from gear side...battery and PDK are disconnected, hoping for some kind of miracle reset. I hear a light ca-thunk ca-thunk pump sound I’ve never heard before coming from the PDK pan. Like an actuator solenoid, but remember the pan is bone dry, probably never heard that because it was submerged in fluid.

I sent you a private message with some information that I found. It seems you need a PIWIS or equivalent to fully service it. Since you didn't mention it I wasn't sure if you have one. Sent from my SM-S908U using Tapatalk

Neil, thanks for pitching in. Can you please share the info you found? That might mean this thread is useful to someone in the future who finds it if they experience the same sort of failure. As far as needing the PIWIS - that is the PDK fill trigger, which pumps oil into the solenoids in the transmission. Supposedly - if one only drains and refills the same amount of magic oil that was drained, that doesn't have to be done. The idea being that the solenoids won't drop their load of fluid just by being exposed with no fluid in the pan. There must be some validity to this since the dry and wet fill quantities differ (by about 2 liters I think - meaning some is in the control circuits and the clutches even after draining it.) I question if that's the case for a high-mileage PDK, since seals might show some wear on the solenoids. @Damitd67 said "3 quarts came out of the PDK clutch side, 3 went in." While that should mean the PDK was full, I wonder if the control circuits had leaked down somehow due to worn seals and that triggered the "trans emergency" when the engine was started up. What I can't understand is the apparent movement of fluid from the PDK control/clutch side to the mechanical transmission side. I can't imagine any seal between the two sides is pressurized on one side, but I also can't say with 100% certainty that it isn't. If it was me (and obviously it isn't) what I'd do at this point is have the dealer perform the fluid change once again. It will probably cost $500 - but they have the PIWIS and can do the fluid fill routine (IIRC my Foxwell NT530 also has that option..) which also includes pan removal (and replacement - for the built-in filter.) It might be useful to have them also drop the valve body and allow the solenoids to drain THEN do the fill routine. Just for reference.. BTW - @Damitd67 - what's your name? Referring to you as Damit is going to get tedious.. And I understand entirely why you bought the car, the same boat sailed here too. 1 - 7 of 7 Posts

For those that asked what I found. While you can do the job without a PIWIS or Durametric or Foxwell , it makes the job easier if you have or can rent or borrow one. "How To Change PDK Clutch Oil on a Porsche Boxster & Cayman (2009-2012) - eCarGuides" How To Change PDK Clutch Oil on a Porsche Boxster & Cayman (2009-2012) - eCarGuides Sent from my SM-S908U using Tapatalk

I would pull the plug on the clutch side as well when you add fluid. If its not coming out that side you've found your issue. If you're have it in the clutch pan until you start it and it is emptied once you start the car, then there is a narrow list of what they problem(s) could be...no fun ones though.

Wondering if you posted this challenge on ********.

WHY in the world would he do that? (See my sig...) There isn't much expertise left there, most of the good guys came over here.

I did my maintenance last year using this guys video. Anyone watched this? Now I’m worried…

I am now shopping a PDK Cayman so gathering info. I thought that guys approach to everything seemed very straight forward and simple. I’ve read a lot of PDK stuff. Why are you worried? Anyone that kills the car for an oil change by pulling the fuel pump fuse is a caring mechanic! Never heard that one before. C.

For what it is worth- I would NEVER hook a foxwell up to a 987.2. Ask me how I know.... My local indy had to work for several hours to correct all the things it screwed up on my 09 base PDK.