Porsche Cayenne Gearbox Strip and Rebuild

Spent a very interesting lunch hour today with the gearbox technician currently rebuilding the Aisin Warner 09D transmission from my 2004 Porsche Cayenne S (V8 model with 6-speed Tiptronic/automatic).

Porsche Cayenne Gearbox Rebuild Transmission Ferdinand

I got the call at 11.30 that the transmission was out and coming apart. Ninety minutes later I was there with my camera. It was educational to say the least! Even had a demo of the valve body in action: quite fascinating.

Porsche Cayenne Gearbox Rebuild Transmission Ferdinand (4)

The strip revealed no jammed clutch plates as was first suspected. One clutch pack has completely melted with some damage obvious on another. Other than that, it looks lovely in bits and I have every confidence that it will be mega to drive once repaired.

Porsche Cayenne Gearbox Rebuild Transmission Ferdinand (6)

The technician reported that it would not change from first on his test drive. I didn’t have that problem when I drove it around the car park before the recovery truck arrived: it was flicking through 1,2 and 3 fine. My issue was all in the high gears: no drive in 4, 5 or 6.

Porsche Cayenne Gearbox Rebuild Transmission Ferdinand (5)

No matter now as it is in pieces and will be fully rebuilt. The torque converter has gone off to be reconditioned and that is unlikely to be back until Friday. So it will be next week for a pickup. I don’t mind, as we are taking the M3 on our annual pilgrimage to Essen. Cayenne back next week – awesome.

2 Comments

  • Mark says:

    So what’s does a rebuild for a Cayenne set you back? I have been thinking about picking up a used Cayenne. Are transmissions an issue with these?

    • John Glynn says:

      Hi Mark, in the UK you’re looking circa £2k for a total rebuild inc fitting and warranty. The 09D transmission will show valve body wear as the miles climb, which is a £400 recon plus fitting but that’s really a maintenance item: the valve body does a huge amount of work regulating internal gearbox pressures.

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