Assembling Drive Shaft

Information 

Position the new bellows

• at the marking you made earlier on the drive shaft (see also >> Disassembling Drive Shaft   <<). 
• in the grooves provided. 

The drive shaft is assembled in reverse order.

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

Use new circlips and ensure that they are seated correctly.

1. Clamp the joint (use aluminum protective jaws). Carefully slide the new circlip onto the shaft from above.
2. Press the circlip together as far as required so that the joint slides over it easily when you tap it with a rubber hammer. Hold the drive shaft and joint pin with both hands and fit the joint pin onto the drive shaft under the workshop press until the pressure increases (this is as far as it can go). Check the pressure gauge! > Contact force + 8 kN  Do not exceed the maximum force for pressing in joints (8 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. 

   Joint on transmission side: Grease the joint using the quantities of grease specified in the table (new joints are already greased).

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Inner end of drive shaft (shown as an example)

   Joint pin on wheel side: Grease the joint using the quantities of grease specified in the table. (New joints are already greased).

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Outer end of drive shaft

   Engine type Quantity of grease on joint at the wheel side Quantity of grease on joint at the transmission side
   V6 (not PHEV)	> Pre-greased 45g	> Pre-greased 45g
   V6 PHEV	Required grease 35g  Total quantity 80g + 10g	Required grease 35g  Total quantity 80g + 10g
   R4 PHEV
   V8 (not PHEV)	> Pre-greased 53g  Required quantity 30g  Total quantity 83g + 10g	> Pre-greased 53g  Required grease 30g  Total quantity 83g + 10g
   V8 PHEV	> Pre-greased 80g  Required grease 40g  Total quantity 120g + 10g	> Pre-greased 80g  Required grease 40g  Total quantity 120g + 10g

3. Fit hose clamps for the bellows using > V.A.G 1275A - hose clip pliers  .