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Home >> Porsche >> 2012 >> Boxster S, Automatic DCT Trans >> Repair and Diagnosis >> Drivelines & Axles >> Axle Shafts >> 42 - Rear Wheel Suspension, Drive Shafts -- 987-BOXSTER-CAYMAN >> WM 422855 Replacing Bellows Drive Shaft (Except CAYMAN Black Edition, CAYMAN S Black Edition, BOXSTER Black Edition, BOXSTER S Black Edition, CAYMAN R) >> Replacing Bellows Drive Shaft

Replacing Bellows Drive Shaft

Fig 1: Disassembled View Of Drive Shaft
G09587574Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Clamp or clip, small
  2. Clamp or clip, large
  3. Lid
  4. Halfshaft flange
  5. Circlip
  6. CV joint
  7. Boot
  8. Clamp or clip, small
  9. Clamp or clip, large
  10. Boot
  11. Profile shaft
  1. Mark the drive shafts (position of bellows).

    Before disassembly, mark the correct position of the bellows for re-installation -arrow-  .

    Fig 2: Locating Bellows Marking On Drive Shaft
    G09587575Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Do not remove bellows holder on wheel-side joint.

    Replacing CV joints: only the transmission-side CV joint is supplied. Otherwise the entire drive shaft must be replaced.

  2. Remove CV joint on transmission side.
    1. 2.1. Remove circlip for CV joint using suitable circlip pliers, e.g. circlip pliers vw 161 a  .
      Fig 3: Identifying Circlip Pliers
      G09587576Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 2.2. Press off the CV joint using special tools -1, 2- press tool vw 408 a  and thrust plate vw 401 a  . Push dust bellows and bellows holder to the inner side of the drive shaft so that the CV joint can be pressed off.
      Fig 4: Pressing Off CV Joint Using Special Tool
      G09587577Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Remove outer bellows.
    1. 3.1. Remove clamp and/or clip (depending on design) -1 and 2-  .
    2. 3.2. Push the bellows off the profile shaft. Then force off the cap -3-  and bellows holder -4-  evenly using a suitable mandrel.
      3. Fig 5: Identifying Outer CV Joint
      G09587578Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Grease CV joints.

    Regrease the CV joints with special grease if necessary . On the wheel-side joint, press -special grease-  through the bellows holder into the joint.

    Fig 6: Applying Grease On CV Joint
    G09587579Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Do not remove bellows holder on wheel-side joint.

    The CV joints must be able to be move slightly in an axial direction (length compensation).

  5. Push inner and outer bellows and clamps or clips onto profile shaft.
  6. Install CV joints.
    1. 6.1. Push or press the CV joint onto the correct position on the profile shaft using a suitable pressure piece -3-  .
      Fig 7: Pressing CV Joint Using Tool
      G09587580Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 6.2. Use new circlip.

      Install circlip for CV joint with suitable circlip pliers, e.g. circlip pliers vw 161 a  .

      Fig 8: Identifying Circlip Pliers
      G09587581Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Install lid.
    1. 7.1. Coat sealing surface of lid -arrow-  and bellows holder with special sealant .
      Fig 9: Locating Grease Applying Area On Lid
      G09587582Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 7.2. Push on lid and bellows holder evenly from inner CV joint at congruent holes (holes for the fastening screws) with a plastic hammer (do not use force).
  8. Position and secure the bellows according to the markings applied earlier -arrows-  . To do this, tighten the clips and clamps.

    Tighten the clamps using the hose clip pliers vag 1275  or commercially available special pliers.

    Fig 10: Locating Bellows Marking On Drive Shaft
    G09587583Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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