Installing Rear Cardan Shaft

→ When one of the two flanges on the cardan shaft has been released, relieve the tension on the centre bearing.

→ Do not leave the cardan shaft hanging. Always screw in all three fastening points for transmission, centre bearing and rear final drive.

→ Follow the recommended procedures during installation, otherwise the position of the cardan shaft in its original place is no longer guaranteed.

→ Carefully remove and install the dowel sleeve.

→ Grease the dowel sleeve slightly during installation.

→ Transmission journal must be clean.

Information 

• To prevent the cardan shaft from being damaged, a second mechanic is required to install the equipment. 

Information 

• There is no colour marking on the flange to the transfer box for installing new components, transfer box or cardan shaft. As a result, positioning is not an issue. 
• If none of the components are replaced, the mark you apply is a precautionary measure in order to avoid humming noises from the drive line. 

Information 

• To attach the cardan shaft to the rear axle transmission, a second fitter should counter the fastening screws on the triangular flange of the transfer box. 
• Screws which are tightened with a torque angle must be replaced with new ones. 

1. Install cardan shaft.
2. Pull cardan shaft joints apart so that they sit in the transmission flanges.
3. Position six new  screws -arrow-  on the centre bearing holder but do not tighten.
   Fig 2: Locating Cardan Shaft Centre Bearing To Body Fastening Screws

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4. Position the cardan shaft at the colour markings -arrow-  again.
   Fig 3: Locating Marking On Transfer Gear Flange/Cardan Shaft

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   Information 

   • The colour marking, match point -arrow- , on the cardan shaft and on the flange of the rear final drive must be aligned. This will neutralise the residual imbalance of the components. 
     Fig 4: Locating Match Points On Cardan Shaft To Final Drive

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5. Tighten new screws for cardan shaft flange on the rear axle differential. → Initial tightening: 30 Nm (22 ft lbs.)  → Final tightening: 90° 
   Fig 5: Identifying Cardan Shaft To Rear Final Drive Fastening Screws

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6. Tighten bolts connecting cardan shaft triangular flange to transfer gear -arrows-  . Counter with an open-ended wrench. → Tightening torque: 75 Nm (56 ft lbs.) 
   Fig 6: Locating Cardan Shaft To Transfer Gear Fastening Screws

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7. New fastening screws must be used to secure the cardan shaft centre bearing holder to the body -arrows-  . → Tightening torque: 60 Nm (44 ft lbs.) 
   Fig 7: Locating Cardan Shaft Centre Bearing To Body Fastening Screws

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   Information 

   • Centre bearing must be installed without tension. 
   • Fit special tool centring tool 9680  in position in the specified sequence.
     Fig 8: Identifying Special Tool Installation Position

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8. Mount special tool centring tool 9680 -arrow, inset-  .
   Fig 9: Mounting Special Tool 9680

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9. Press on special tool centring tool 9680  in sequence according to numbering -1, 2-  .
   Fig 10: Pressing Special Tool 9680

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10. Tighten bolts -arrow-  securing holder to centre bearing. → Tightening torque: 20 Nm (15 ft lbs.) 
    Fig 11: Locating Cardan Shaft Support To Centre Bearing Fastening Screws

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11. Remove special tool centring tool 9680. -arrows- 
    Fig 12: Removing Special Tool 9680

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