Assembling drive shaft

CAUTION: Watch out for falling parts during disassembly work.

Possible danger of injury or damage.

→ Wear protective gear (e. g. safety shoes, gloves).

→ 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 fit the joint as far as it will go by hitting it several times with a hammer. See Fig 1.

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. See Fig 4.

Fig 5: Fitting cap

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Before replacing the cap (transmission side), fill in the required amount of grease. Seal the sealing faces with special sealant (refer to Spare Parts Catalogue). When fitting the cap, use two cheese-head bolts for fixing. Tap on alternate sides with a rubber hammer in order to fit the cap in the correct position. See Fig 5.