31 60 003 Removing and installing or replacing left output shaft

Special tools required:

31 4 170

Remove FRONT WHEELS .

IMPORTANT: Expand turning lock sufficiently to avoid damaging thread when releasing collar nut.

Release collar nut (1), press brake pedal to floor for this purpose.

Fig 1: Identifying Collar Nut

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Remove LEFT MICROFILTER HOUSING COVER

IMPORTANT: Use special tool to avoid preliminary damage to ball joint in upper control arm.

Press plugs out of spring strut dome.

Secure swivel bearing (1) with special tool 31 4 170 in installation position.

Fig 2: Identifying Special Tool (31 4 170) In Installation Position

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Remove REINFORCEMENT PLATE .

Remove steering gear cover at top and bottom. See 51 71... REMOVING AND INSTALLING/REPLACING BOTTOM LEFT OR RIGHT STEERING GEAR COVER , 51 71... REMOVING AND INSTALLING/REPLACING TOP LEFT STEERING GEAR COVER , and 51 71... REMOVING AND INSTALLING/REPLACING TOP RIGHT STEERING GEAR COVER .

Remove LOWER CONTROL ARM FRONT SPRING STRUT HOLDER AND FRONT AXLE CARRIER .

Press OUTPUT SHAFT OUT OF DRIVE FLANGE .

IMPORTANT: Risk of damage!
Tape off output shaft and secure against falling off.

When removing output shaft, make sure that tripod does not fall into gaiter.

Turn steering wheel to right.

Press swivel bearing slightly to one side and remove output shaft from wheel bearing.

Press output shaft with a suitable tool out of front differential and remove between spring strut holder and control arm.

Fig 3: Pressing Output Shaft With Suitable Tool Out Of Front Differential

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Installing output shaft:

Replace shaft seal in front differential. See 31 51 015 REPLACING SHAFT SEAL FOR LEFT OUTPUT SHAFT and 31 51 020 REPLACING SHAFT SEAL FOR RIGHT OUTPUT SHAFT .

Check FRONT DIFFERENTIAL OIL LEVEL , correct if necessary

IMPORTANT: High installation forces indicate that the output shaft spline teeth are damaged or deformed!

Check spline teeth, replaced damaged parts.

Replace circlip (1).

Coat highlighted contact surface (2) of output shaft with approved front differential oil.

Fig 4: Identifying Circlip And Output Shaft

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IMPORTANT: When installing output shaft, make sure that tripod does not fall into gaiter.

Press swivel bearing slightly to one side and insert output shaft into front differential.

Pull out assembly protection ring at lug (1) until one of the two programmed rupture points gives.

Slide output shaft as far as it will go into front differential. Output shaft must snap audibly into place.

Fig 5: Identifying Protection Ring

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Press swivel bearing slightly to one side and insert output shaft into wheel bearing.

Move steering to straight-ahead position.

Fig 6: Moving Steering To Straight-Ahead Position

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Draw OUTPUT SHAFT INTO DRIVE FLANGE .

Install LOWER CONTROL ARM .

Install REINFORCEMENT PLATE .

Remove special tool 31 4 170 for swivel bearing (1).

Use plugs from spring strut dome.

Install LEFT MICROFILTER HOUSING COVER

Fig 7: Identifying Special Tool (31 4 170) In Installation Position

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Replace collar nut (1), oil collar nut/wheel bearing contact surface only and tighten down.

No oil permitted on thread of shaft journal or collar nut.

Tightening torque 31 21 2AZ .

Secure collar nut by positive peening on flat areas of output shaft.

Install FRONT WHEELS .

Fig 8: Identifying Collar Nut

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After installation:

Perform chassis alignment check. See 32 00 150 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH LOAD UP TO DESIGN POSITION or 32 00 155 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH RIDE-HEIGHT MEASUREMENT WITHOUT LOAD
Carry out steering angle sensor adjustment/adjustment for active front steering. See 32 10 005 ADJUSTMENT FOR ACTIVE FRONT STEERING and 61 31 996 CARRYING OUT STEERING ANGLE SENSOR ADJUSTMENT .