LEMON Manuals: Even more car manuals for everyone
Home >> Porsche >> 2016 >> Boxster Base, Automatic DCT Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 274 (42 Rear Wheel Suspension, Drive Shaft -- 911 CARRERA (991)) >> WM 422855 Replacing Drive Shaft Bellows (Except CARRERA "Edition", CARRERA Cabriolet "Edition", CARRERA 4 "Edition", CARRERA 4 Cabriolet "Edition") >> Replacing Drive Shaft Bellows

Replacing Drive Shaft Bellows

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2019 Porsche 911, 2018 Porsche 911, 2017 Porsche 911, 2016 Porsche 911, and 2015 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Drive Shaft Components
G09992958Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Clamp (clip), small
  2. Clamp (clip), large
  3. Cover
  4. Bellows holder
  5. Circlip
  6. Constant-velocity joint
  7. Bellows
  8. Clamp (clip), small
  9. Clamp (clip), large
  10. Bellows
  11. Profile shaft
  1. Mark the drive shaft (position of bellows).

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

    Information 

    • Do not remove bellows holder on the joint on the wheel side. 
    • Replacing constant-velocity joints: Only the constant-velocity joint on the transmission side is available. Otherwise, replace the complete drive shaft. 
      Fig 2: Locating Drive Shaft Bellows Marking Position
      G09992959Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Remove bellows on transmission side.
    1. 2.1. Remove clamps (clips) -1-  .
      Fig 3: Identifying Transmission Side Constant-Velocity Joint
      G09992960Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 2.2. Then force off the cover -3-  and bellows holder -4-  evenly using a suitable mandrel.
    3. 2.3. Move bellows and bellows holder to the wheel side of the drive shaft.
    4. 2.4. Remove circlip -1-  using suitable pliers.
      Fig 4: Identifying Circlip
      G09992961Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    5. 2.5. Press off constant-velocity joint using -1- press tool VW 408 A  and -2- pressure plate VW 401  .
      Fig 5: Pressing Constant-Velocity Joint
      G09992962Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    6. 2.6. Slide bellows and bellows holder off the drive shaft.
  3. Remove bellows on wheel side.
    Fig 6: Identifying Wheel Side Bellows
    G09992963Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 3.1. Remove clamps (clips) -1 und 3-  .
    2. 3.2. Slide bellows -2-  off the drive shaft.

      Information 

      Do not remove bellows holder on the joint on the wheel side.

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

  4. Re-grease constant-velocity joint on the wheel side using special grease if necessary . Grease must be pressed in through the bellows holder into the joint.
    Fig 7: Identifying Wheel Side Constant-Velocity Joint Grease Applying Area
    G09992964Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Fit bellows -2-  on the wheel side on the bellows holder.

    Fit large clamp (clip) -1-  and tighten using pliers Nr.74  or commercially available special pliers.

    Slide small clamp (clip) -3-  onto the drive shaft, but do not tighten yet.

    Fig 8: Identifying Wheel Side Bellows
    G09992965Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Re-grease constant-velocity joint on the transmission side using special grease if necessary .
  7. Slide clamps for bellows onto the profile shaft.
  8. Assemble bellows with bellows holder.
    1. 8.1. Coat sealing face of the bellows holder -arrow-  with special sealant .
      Fig 9: Locating Bellows Holder On Transmission Side
      G09992966Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 8.2. Tap bellows holder evenly onto the constant-velocity joint at congruent holes (holes for the fastening screws) using a plastic hammer (do not use force).

      Tap on bellows holder on the side of the constant-velocity joint with the groove -arrow-  .

      Fig 10: Installing Bellows Holder On Constant-Velocity Joint
      G09992967Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  9. Assemble constant-velocity joint and bellows -1-  with the profile shaft -2-  .
    Fig 11: Pressing Constant-Velocity Joint
    G09992968Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 9.1. Tap or press the constant-velocity joint -1-  using a suitable pressure piece -3-  so that it fits onto the profile shaft -2-  at the correct position.
    2. 9.2. Fit new circlip using suitable pliers.
  10. Install cover on the transmission side.
    1. 10.1. Coat sealing face of the cover -arrow-  with special sealant .
      Fig 12: Locating Transmission Side Coating Cover
      G09992969Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 10.2. Tap cover evenly onto the constant-velocity joint at congruent holes (holes for the fastening screws) using a plastic hammer (do not use force).
  11. Position bellows according to the marking applied previously -arrow-  . Tighten clamps (clips) at this position using pliers Nr.74  or commercially available special pliers.
    Fig 13: Locating Drive Shaft Bellows Marking Position
    G09992970Courtesy of PORSCHE CARS NORTH AMERICA, INC.
scientia non olet · About LEMON Manuals