Replacing Bellows Drive Shaft

WARNING: This page does not describe the selected car, but rather 10 other vehicles, including the 2012 Porsche Cayman, 2012 Porsche Boxster, 2011 Porsche Cayman, 2011 Porsche Boxster, and 2010 Porsche Cayman. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Disassembled View Of Drive Shaft

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Clamp or clip, small
Clamp or clip, large
Lid
Halfshaft flange
Circlip
CV joint
Boot
Clamp or clip, small
Clamp or clip, large
Boot
Profile shaft

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
Courtesy 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.
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
  Courtesy 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
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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.
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
Courtesy 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).
Push inner and outer bellows and clamps or clips onto profile shaft.
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
  Courtesy 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
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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
  Courtesy 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).
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
Courtesy of PORSCHE CARS NORTH AMERICA, INC.