31 60 003 Removing and installing/replacing left output shaft

Special tools required:

31 4 170

IMPORTANT: On four-wheel drive vehicles with defective, non-engaging drive, it is imperative that the following information is taken account of:

See ADDITIONAL WORK WHEN REPLACING OUTPUT SHAFT .

Necessary preliminary tasks:

Remove FRONT WHEEL .
Remove LEFT MICROFILTER HOUSING COVER
Remove REINFORCEMENT PLATE .
Remove STEERING GEAR COVER AT TOP LEFT .

IMPORTANT: Expand anti-twist lock sufficiently to avoid damaging thread when releasing collar nut.

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

Tightening torque 31 21 2AZ .

Installation note:

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.

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

Fig 1: Identifying Collar Nut

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IMPORTANT: Use special tool to avoid preliminary damage to the ball joint in the upper wishbone!

Press plugs out of spring strut dome.

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

Fig 2: Identifying Swivel Bearing And Special Tool (31 4 170)

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

Use two tire levers on both sides to push the drive shaft out of the front axle differential.

Remove drive shaft from between suspension strut mounting and control arm

Fig 3: Removing Output Shaft From Wheel Bearing

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Replace RADIAL SHAFT SEAL IN FRONT AXLE DIFFERENTIAL .
Check FRONT AXLE GEARBOX OIL LEVEL , correct if necessary.

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

Check splines and replaced parts if damaged.

Install retaining ring (1).

Coat highlighted contact surface (2) of output shaft with APPROVED OIL .

Fig 4: Identifying Output Shaft Circlip And Contact Surface

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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 predetermined breaking points gives.

Fig 5: Identifying Assembly Protection Ring Lug

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Slide output shaft to the limit position into front axle differential. Output shaft must snap audibly into place.

After installation:

Carry out WHEEL ALIGNMENT PROCEDURE .