Assembling Drive Shaft

Information 

• Do not use cleaning agents on the joints (as these have a thinning effect on grease!). 
• Joints must be replaced following removal. 
• Protective ring (on transmission side) must be replaced following removal. 
• Circlips must be replaced following removal. 
• Carry out a close visual inspection of parts to be re-used. 

1. Use > V.A.G 1682A - clamp tensioner  to secure the new clamps.
2. Position all bellows and new clamps on the profile shaft.

   Information 

   • Do not exceed the maximum contact force when pressing in the drive shaft.  > Contact force + 20 kN 
   • The procedure for fitting the inner and outer joint is identical. 
3. Install joints.
   1. 3.1 Clamp the relevant joint using aluminium protective jaws.
   2. 3.2 Slide new  circlip carefully onto the shaft from above, then check that it is seated correctly.
   3. 3.3 Press the circlip together as far as required so that the relevant joint slides over it easily when you tap it with a rubber hammer.
   4. 3.4 Hold the profile shaft and joint pin with both hands and fit the joint pin (as far as it will go) onto the drive shaft under the workshop press until the pressure increases.

   Information 

   • The complete drive shaft is supplied straight from the factory with the quantities of grease specified in the table. 
   • The special grease must be pressed well into the ball tracks of the joint. 
   • Make sure that as little special grease as possible gets into the drive shaft boots. 
   • Make sure to position the bellows correctly when sliding them on. 
4. Grease joints.
   1. 4.1 Grease inner joint (on transmission side) using the amount of grease specified in the table. > Inner drive shaft (shown as an example) 
      1. 4.1.1 Press the required amount of grease outwards through the joint, then grease the inside of the joint.

         Courtesy of PORSCHE CARS NORTH AMERICA, INC.

         Inner drive shaft (shown as an example)

      2. 4.1.2 Remove excess grease with a lint-free cloth.
      3. 4.1.3 Align the bellows according to the markings made during removal and slide it onto the joint.
      4. 4.1.4 Tighten large clamp.

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   2. 4.2 Grease inner joint (on transmission side) using the amount of grease specified in the table. > Outer drive shaft (shown as an example) 
      1. 4.2.1 Press the required amount of grease outwards through the joint, then grease the inside of the joint.

         Courtesy of PORSCHE CARS NORTH AMERICA, INC.

         Outer drive shaft (shown as an example)

      2. 4.2.2 Remove excess grease with a lint-free cloth.
      3. 4.2.3 Align the bellows according to the markings made during removal and slide it onto the joint.
      4. 4.2.4 Tighten large clamp.

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5. Secure the small bellows clamps.
   1. 5.1 Push the joint from stop to stop and centre it.

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      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Bellows positioning

   2. 5.2 Secure the small clamp and repeat the procedure for the other joint.

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