Assembling Drive Shaft

→ Secure components to prevent them from falling down.

→ Secure components to prevent them from falling down.

The drive shaft is assembled in reverse order.

Check all parts to be re-used carefully.

Before fitting the joint, slide all boots, hose clamps and other clamps on to the drive shaft.

Do not confuse the boots. They are not identical parts.

Use new circlips and ensure that they are seated correctly.

1. Clamp the drive shaft (use aluminium protective jaws). Position an aluminium mandrel on the ball hub (star-shaped inner ring) and fit the joint -siehe illustration-  as far as it will go by hitting it several times with a hammer.
   Fig 1: Fitting Joint

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Fit the joint pin as far as it will go on to the drive shaft.

   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. 

   Regreasing joints:

   Regrease the 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)
   V6/V8	190	120

   Joint on transmission side: regrease as required, depending on the amount of grease left in the joint. Before replacing the cap, fill in the required amount of grease.

   Fig 2: Greasing Inner Drive Shaft

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint pin on wheel side: regrease as required, depending on the amount of grease left in the joint. The joint pin is supplied ex-works with approx. 80 grams of grease at the outside and approx. 40 grams at the inside. Remove excess grease with a lint-free cloth. Push the required amount of grease through the joint to the outside. Then grease the inside of the joint.

   Fig 3: Greasing Outer Drive Shaft

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Fit the large hose clamps for the two boots. The hose clamp lug - on the transmission side - must be positioned between two bores on the joint.
4. Fit the small hose clamps for the two boots between the grooves. If the boots are fitted correctly, the groove -A-  will be visible.
   Fig 4: Identifying Grooves In Drive Shaft

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Fill in the appropriate quantity of grease before fitting the cap (on the transmission side). Seal the sealing faces with special sealant. When fitting the cap, use two cheese-head bolts for fixing -siehe illustration-  . Using a rubber hammer, alternate between striking one side of the cap and then the other in order to fit it in the correct position.
   Fig 5: Fitting Cap Using Rubber Hammer

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.