Replacing Bellows Drive Shaft

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2013 Porsche 911, 2012 Porsche 911, 2011 Porsche 911, 2010 Porsche 911, and 2009 Porsche 911. 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 drive shafts.
Required only for monobloc drive shafts: before disassembling the shaft in the case of monobloc drive shafts, the correct position of the bellows must be marked for reinstallation -arrow- .

Fig 2: Locating 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 CV joint using special tools -1, 2- plunger vw 408 a and pressure 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
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove outer bellows.
1. 3.1. Remove clamp and/or clip (depending on the design) -1 and 2- .
2. 3.2. Push bellows off profile shaft. Then force off lid -3- and bellows holder -4- evenly with a suitable mandrel.
Fig 5: Identifying Outer CV Joint
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Grease CV joints.
Regrease the CV joints with special grease if necessary . On the wheel-side joint, press -the special grease- through the bellows holder into the joint.

Fig 6: Greasing 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 CV joint onto the profile shaft in the correct position using a suitable pressure piece -3- .
  
  Fig 7: Pressing On CV Joint
  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: Greasing 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 bellows.

Fig 10: Locating Marking On Drive Shaft
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 8.1. In monobloc drive shafts in accordance with the marking that was made previously -arrows- . In friction-welded drive shafts, between the relevant depressions.
2. 8.2. Tighten clips or clamps.
  Tighten the clamps using the special pliers vag 1275 or a commercially available special pliers.