Assembling Drive Shaft: Assembly

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WARNING: Danger of objects or loads falling down

Risk of squashing or crushing

→ Secure components to prevent them from falling down.

The drive shaft is assembled in reverse order.

Check all parts to be re-used carefully.

Always replace the removed joints.

Before fitting the joint, slide all bellows, hose clamps and other clamps onto the profile shaft.

Use new circlips and ensure that they are seated correctly.

Use a new protective ring (on transmission side). Check that it is fitted correctly.

Clamp the new joint (use aluminum protective jaws).
Carefully slide the new circlip into the groove on the profile shaft from the side.

Insert profile shaft into the joint. Press the circlip together (pre-centre it) as required so that the profile shaft can be inserted easily when you tap it with a rubber hammer. Hold the profile shaft and joint pin with both hands and fit the joint pin onto the profile shaft under the workshop press until the pressure increases (this is as far as it can go). Check the pressure gauge! → Contact force: +20 kN Do not exceed the maximum force for pressing in joints (20 kilonewtons/2 tonnes)!

The procedure for fitting both joints is identical.

Information

Do not use cleaning agents on the joints (grease thinners!) .
Always replace the removed joint at least during assembly .
Press the grease with a sufficient amount of force into the ball tracks of the joint .
Make sure that only a small amount of grease gets into the drive shaft boots .

Greasing joints:

Grease joints with special grease . The original grease quantities for the individual joints are specified in the following table.

Vehicle	Joint, inner (gram)	Joint pin, outer (gram)
Without rear differential lock (Not for Diesel S/Turbo vehicles)	80	80
With rear differential lock For Diesel S/Turbo vehicles without rear differential lock	85	85

Joint on transmission side: Grease the joint using the quantities of grease specified in the table. The complete drive shaft is supplied straight from the factory with the quantities of grease specified in the table. Before sliding on the bellows, remove excess grease using a lint-free cloth. Push the required amount of grease through the joint to the outside. Then grease the inside of the joint.

Fig 1: Greasing Inside Of Drive Shaft

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Joint pin on wheel side: Grease the joint using the quantities of grease specified in the table. The complete drive shaft is supplied straight from the factory with the quantities of grease specified in the table. Before sliding on the bellows, remove excess grease using a lint-free cloth. Push the required amount of grease through the joint to the outside. Then grease the inside of the joint.

Fig 2: Greasing Outer Drive Shaft

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Position the new bellows

at the marking you made earlier on the drive shaft (see also >> DISASSEMBLING DRIVE SHAFT , Step 1 <<) .
Always comply with the specified dimension .

Fit small hose clamps for both bellows. If the bellows are fitted correctly, the groove -A- will be visible.

Fig 3: Identifying Grooves On Drive Shaft
Courtesy of PORSCHE CARS NORTH AMERICA, INC.