Assembling drive shaft

CAUTION: Danger of injury. Look out for falling parts during disassembly work. Get another worker to help.

→

The drive shaft is assembled in reverse order.

Check all parts to be re-used carefully.

Before fitting the joint, slide all boots, hose clamps and other clamps on to the drive shaft.

Use new circlips and ensure that they are seated correctly.

Fig 1: Fitting the joint

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Clamp the drive shaft (use aluminum protective jaws). Position an aluminum mandrel on the ball hub (star-shaped inner ring) and use forceful hammer blows to drive the -joint- up to the stop.

NOTE:

Before regreasing, remove excess grease with a lint-free cloth. Do not use cleaning agents on the joints (grease thinners!).
Make sure that only a small amount of grease gets into the bellows. This grease is not relevant for the actual lubrication of the joint.

Regreasing joints:

Regrease the joints with special grease (refer to Spare Parts Catalogue). The original grease quantities for the individual joints are specified in the following table.

Vehicle	Joint, inner (gram)	Joint pin, outer (gram)
V6	100	100
V8	135	135
Vehicles with differential lock	135	135

Fig 2: Greasing inner drive shaft

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Joint on transmission side: regrease as required, depending on the amount of grease left in the joint. Before replacing the cap, fill in the required amount of grease.

Fig 3: Greasing outer drive shaft

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Joint pin on wheel side: regrease as required, depending on the amount of grease left in the joint. Remove excess grease with a lint-free cloth. Push the required amount of grease through the joint to the outside. Then grease the inside of the joint.

2. Fit the large hose clamps for the two boots. The hose clamp lug - on the transmission side - must be positioned between two bores on the joint.

Fig 4: Grooves in drive shaft

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Fit the small hose clamps for the two boots. If the boots are fitted correctly, the groove -A- will be visible.

Fig 5: Fitting cap

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Fill in the appropriate quantity of grease before fitting the cap (on the transmission side). Seal the sealing surfaces with special sealant (see Spare Parts Catalogue). When fitting the cap, secure it in place with -two pan-head screws- . Using a rubber hammer, alternate between striking one side of the cap and then the other in order to fit it in the correct position.