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04 Cayenne Build

rabbit7
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rabbit7 Member

rabbit7

Posted
Posted

Hey guys, New to the forum and just started a tear down and build of my new 04 cayenne TT. All work is done in my own garage by myself. Pictures to come shortly. This is a build with time constraints. This is my daily drive so i need everything done by Monday! Here is the list of thing's i am working on:

Valve Body has been removed, sent to Revmax for a rebuild and sent back. Transmission filter and gasket did not arrive with valve body. Revmax sent it out and should arrive tomorrow. VB Retaining bolts have been ordered from my nearest dealer. Should be ready for pick up Friday. (i hope!)

Intake, Plenum, and secondary cat deletes ordered from EVO. Evo sales have been Great!! all packages were ordered Wednesday and will arrive on Friday!

Diverter valves ordered from GMP and will arrive Friday.

ATF Redline D4, Castrol SRF brake fluid, and Redline 75w90 for diff ordered from summit racing and should arrive today. Hopefully i can start the brake flush today. Never done it before but there is a first time for everything.

Stock 20" rims Removed and sent to Sever Metals in Oakley, Ca for powder coating. Should be complete and ready for pick up today or Friday.

Stripping interior down for a good cleaning. Polished aluminum trim on shifter knob. Tried to polish trim around the shifter but broke the plastic trying to remove it. Just so happens i found one on ebay already polished!! ordered and hoping for a Saturday arrival.

Cleaning all brake and suspension parts and repainting calipers. Looks like the previous owner was not a car guy!

As you can see i have a lot of work to get done this weekend!! This forum has also helped a lot!!! Thanks everyone!

rabbit7 Member

rabbit7

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  • Author
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Diverter valves arived ahead of schedule!!! Packaging is great, nice foam cut out. Valves look good. They have a great finish. Time to install

post-94280-0-15372600-1395947741_thumb.j

post-94280-0-51457300-1395947755_thumb.j

post-94280-0-73422200-1395947767_thumb.j

rabbit7 Member

rabbit7

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Heres a picture of the polish knob trim. Any one know a good way to get swirls and scratches out of the wood grain trim? Tried rubbing compound, machine compound, didn't really help. Any Ideas?

post-94280-0-07306500-1395947835_thumb.j

post-94280-0-11705400-1395947910_thumb.j

rabbit7 Member

rabbit7

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  • Author
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Valves installed. Passenger side was easy but the driver side as a pain. Autozone sells a tool for the oem hose clamps. Has a extended cable and clamp. 30 bucks and worked great!! Both Wheel well covers needed to be removed. Valves can really only go in one way due to the position of the 1/4" nipple. Just remember which way that faced and you wont install it backwards. the valves are bigger than the oems so im a little worried about the other hoses in the install area rubbing. Well see if there's any issues. Wish i could start her up!! post-94280-0-11845400-1395955335_thumb.j Oem Vs APR

post-94280-0-81456400-1395955523_thumb.jpassenger valve

post-94280-0-81536200-1395955506_thumb.jDriver side valve. You can barely see it

post-94280-0-42095900-1395955537_thumb.jPassenger Valve installed

Edited by rabbit7
rabbit7 Member

rabbit7

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Just changed the Diff fluid front and rear, Working on the transfer case. The Fill plug was Ridiculously tight!!! Had to use a 3ft breaker bar. I stripped the plug a little bit so i will need to get a replacement soon. Surprisingly the oil that came out was black. No were near as red as the ATF fluid. I thought they were the same. Could just be really dirty. Got a question. How bad is it to use the Old Valve body retaining bolts? Do they really need to be replaced?

clarksongli Member

clarksongli

Posted
Posted

Just changed the Diff fluid front and rear, Working on the transfer case. The Fill plug was Ridiculously tight!!! Had to use a 3ft breaker bar. I stripped the plug a little bit so i will need to get a replacement soon. Surprisingly the oil that came out was black. No were near as red as the ATF fluid. I thought they were the same. Could just be really dirty. Got a question. How bad is it to use the Old Valve body retaining bolts? Do they really need to be replaced?

Just fyi....The differentials do not take atf..... they take 75 90 or the Burma spec oil called out by porsche.....only the transfer case takes atf

rabbit7 Member

rabbit7

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Yup got it thanks!!cat deletes just arrived. They are freakin beautiful!!! EVOMS helped out alot getting the parts here. Intake and plenum should arrive shortly. I did get screwed on the rims though. They will be ready for pick up tommorrow. Hopefully. ..

rabbit7 Member

rabbit7

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All parts are here!!!! time for the fun! Ill start taking picks as everything comes apart. Heres some pics of the exhaust and the rest of the packages.

post-94280-0-20775500-1396055112_thumb.j

post-94280-0-83891600-1396055153_thumb.j

rabbit7 Member

rabbit7

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Alright, Cat deletes are installed. I found it easy to soak all bolts for about 20 min then they came of fairly easy. Driver side flange was a pain The very top bolt is in a tight spot. Had to remove all the hangers and finagle a wrench between the pipe and the shaft. I eventually got it. The one bolt took me about 20 min. All new bolts were doped with anti seize just in case.The driver side hanger may be welded in the wrong location. the hanger shaft is snug up against the rubber as you can see from the pictures. I'm going to send these to EVOMS and see what they think. Valve body is torqued and installed ready for fill. I'm going to cold fill it tonight and then warm fill it tomorrow when i get the rims and can get this thing on the ground. Not to comfortable shifting gears while shes on jack stands. The EVOMS intake looks great. I can see why its so expensive. Going to start work on that next. So far so good!!

post-94280-0-42181700-1396074241_thumb.j Driver side flangepost-94280-0-72093900-1396074256_thumb.j passenger side flange. Very easy. post-94280-0-39215600-1396074271_thumb.jDriver side Mount As you can see its alot closer then stock or the passenger sidepost-94280-0-66165100-1396074289_thumb.jPassenger side mountpost-94280-0-89901300-1396074346_thumb.jEVOMS Intake unpacked

rabbit7 Member

rabbit7

Posted
  • Author
Posted

Just changed the Diff fluid front and rear, Working on the transfer case. The Fill plug was Ridiculously tight!!! Had to use a 3ft breaker bar. I stripped the plug a little bit so i will need to get a replacement soon. Surprisingly the oil that came out was black. No were near as red as the ATF fluid. I thought they were the same. Could just be really dirty. Got a question. How bad is it to use the Old Valve body retaining bolts? Do they really need to be replaced?

Just fyi....The differentials do not take atf..... they take 75 90 or the Burma spec oil called out by porsche.....only the transfer case takes atf

Ya i was trying to explain that the ATF out of the Transfer case was not red at all. Could have just been really really dirty. Replaced the Diffs with Redline 75w 90 . Transmission and Transfer case have Redline D4. Thanks!!!

  • 1 month later...
jagman1 Member

jagman1

Posted
Posted

The factory fill for the transfer case is indeed ATF. The Porsche shop manual makes special mention that "when replacing the fluid in the transfer case the factory fill is blue in color." and that the replacement fluid will be red. That should explain why it looked as it did. I had the same experience when I changed mine.

  • 1 month later...
  • 4 months later...
rabbit7 Member

rabbit7

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  • Author
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Hey Rabbit,

 

What ever happened with this build?  are you done...?

 

What's the outcome?

Sorry everyone for not following up. I had to head out of the country for work. The build went great! The intake and cat deletes really gave the cayenne a great sound. No need to install new mufflers. The only issue that the cayenne has always had is a shakey idle and a pesky P0021 code from the durametric that wont go away. Its not throwning a CEL which makes even more of a PITA. Changed all the coils and spark plugs and its still there. for now im just going to drive it until it gets worse. 

srfrdrew Member

srfrdrew

Posted
Posted

Hey Rabbit7

 

Per your code P0021

P0021 Inlet Camshaft Position in relation to Crankshaft, Bank 2 - Above/Below Limit
Possible cause of fault
- Timing set incorrectly
- Chain extended
- Camshaft adjuster loose
- Rotor of inlet camshaft sensor in incorrect position
- Inlet camshaft sensor not installed correctly

 

ALSO CHECK CONDITION OF YOUR BATTERY!

 

Hey Rabbit, I'm going to replace my Valve Body with a RevMax, do you have a moment to speak with me regarding the installation process (Fluid, VB, etc) maybe speak over phone?

Thanks!

  • 1 month later...

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