I have been mulling over this project for the last year and a half. Considering that I am now approx 50% over the stock power levels, I am forced to ask myself where the power limit is; essentially what will break first? Given the lack of hard facts and the unwillingness to drive over a cliff for specific answers, I am left trying to mitigate any potential issues before they arise.

With that said, right now, I felt my biggest risk was my transmission. I have looked up many specs and everything I have seen says that it was built to only handle 550 hp - no more. That would imply the stock transmission cooler too. Statistically speaking, since 90% of transmission failures are due to heat, I decided that the stock cooling capacity was MOST LIKELY a liability for me. Given the replacement cost easily into the thousands of dollars, I decided I would kick this project into high gear. Especially since I am known to do some light towing ;-)

DISCLAIMER

This thread is not intended for anyone to copy or imitate. I am not endorsing any products or companies. I am merely showing the steps I went through to get this working for me. If you think you want to do something similar, contact your local Porsche dealer and ask for recommendations and proceed at your own risk. I assume no responsibility for any work performed on your vehicle.

SPECIAL NOTE

Given the lengths of some of my most recent threads, I have opted instead for a photo montage punctuated with brief notes.


PHOTO MONTAGE

Vehicle is dirty due to excessive road salt and grime Bumper removed. The stock transmission cooler is at the very top of the cooler stacking. Tranny cooling lines are ran vertically up the left side.

Secondary cooler just hanging out for test fitment.




Closeup of transmission cooling line. We will be intercepting the return line on the right and running it through out secondary cooler, before it returns to the transmission. That way we get the full benefit of both coolers; inline.



Here is the secondary cooler. BM Supercooler 70274 with 1/2 NPT Ports. Over 29,000 BTUs of cooling! I will be using -8AN to 1/2 NPT adapters to the braided stainless steel hose.





Here is the full set of adapters and hose (minus -8AN cooler adapters). Pretty standard, except for the industrial stainless steel compression fittings.



Here is a closeup. Ham-let twin ferrule compression fittings. Stunning quality and WAAAY overrated for this line.



If you are curious, just check out this video here and watch the absolutely insane 25,000 PSI that they are tested it up to:

http://www.youtube.com/watch?v=6uiIWEfjxa4

This is what it will look like once the end nut is placed over the cut line. It will compress with an incredible seal.



New line about to be cut to make space (test cut in middle)



Cutting tool for ~1/2" aluminum pipe



Clean, even cut



Compression fitting being installed in bench vice. Once you compress it, you cannot relocate it without replacing the ferrules.



Installed. No restriction here!







This is how much of the pipe middle section I removed.



Old transmission line, next to new modified transmission line with AN adapters.



The lower pipe is where this return transmission line connects to the thermostat block and then back into the transmission



NPT fittings sealed with pipe dope. OEM fittings reconnected and looks good.



Test fitment for secondary cooler location



Will have to protect this transmission line since secondary cooler rests against it. Do not want the cooler to rub a hole in this line with vibration and time.



7/16" fuel hose - cut length wise



1/8" strip of neoprene gasket material for bottom of secondary cooler. Same purpose.



Protection measures installed.





TIG welding mounting bracket







All done! Had to relocate sensor in the middle of new bracket.





What a weird looking bracket.



Final installation



Matte black everything!









Wow! You can barely see it!

 

Man, if 6speed ever gave out awards for the best thread starter I would nominate you!! This is yet another example of a useful informative thread and the
38 high quality pictures don't hurt either

I've been wanting to do this for some time now. Thanks for the kick in the pants

 

Thanks man! You are too awesome yourself!

No worries - always happy to kick other people /taken-literally

 

Hello sir ! Out of topic , have you ever considered bigger intercoolers? I mean some custom ones by Rob from leistung or Agency Power since they make good value stuff ? Fvd intercoolers are way to expensive now ! Also should we see any gain from the intercoolers since we are maximazing the turbos with intake and exhaust ?

 

Totally amazing craftsmanship. Wow!

 

Thanks!

According to my logging, I was not seeing any alarming air intake temperatures that might increase detonation and subsequent engine retardation. I am currently under the impression that the stock 957 CTT intercoolers are overspec'd in their OEM trim and still adequate a few mods later.

Now that I have the methanol injection, the air intake temps now drop 15-20 degrees F on WOT, so increasing the size of the intercoolers now would give me little gains.

 

Another well executed mod....Diggin the Tig welds brother very nicely done

 

Did your clutch ever slip or transmission valve broke?

also have you ever considered fvd upgraded gt28R Turbos ?

 

Thanks man! Believe it or not, I was rushing through those welds and could care less about weld appearance. I did this whole install in about half a day and was doing my transmission fluid change right after it. It was a Sunday night and had to drive it on Monday into work, so it was all rush-rush.

I guess I built up some skill after TIG welding an entire exhaust system; which was brutal, by the way.

Nope and nope. However, given my power levels are slowing creeping up, I think that both of these would have happened. Hopefully, this cooler will help some of that from happening..

No, those guys who installed those GT28RS turbos did it to achieve 700hp at the crank. This was before anyone realized that the stock turbos can achieve this level of hp, so this would not be a gain for me.

However, I have thought about getting these stock turbos reworked for up to 1000 hp, but sure if I want to take a risk damaging the engine or transmission with that type of power. I have been very lucky being about to mod and make power without sacrificing reliability.

 

Awesome work renassiance man!! I've always enjoyed reading your threads.

 

Thanks! By the way, ECS Tuning is one of my top two suppliers when I need OEM parts. Considering you guys are third party, you have really competitive pricing.

And your transmission fluid change DIY was really helpful

 

Edit:

Going to revisit this transmission cooler since I now have a higher stall torque converter that will generate more heat. Going with a cooler with an electric fan, and adjustable thermostat feature. Final pics coming up soon

 

Such a showoff

 

Have you ever revisited your AT cooler? Any issues in warm up phase without thermostat?
What are the temperatures max/average you see?
Any before/after data?
P. S. I am fully aware that this topic is more than 5 years old but ot doesn't hurt to ask

 

Inquiring minds would also like to know lol. I just got into the Porsche scene with my 08 Cayenne Turbo 957 4.8tt and this entire build has inspired me to do some of the same! I thought there were no options to upgrade our transmissions i.e. valve body upgrade or better torque converter