Installing Rear CARDAN Shaft

Information 

• Use cotton buds or rolled-up pieces of paper towel soaked in brake cleaner to clean the clearance holes and threaded bores.
• Do not blow out the clearance holes and threaded bores with compressed air again after cleaning them.

Information 

• For more information, see Porsche Spare Parts Information.

Information 

The help of another person is required to prevent the cardan shaft in the centre bearing from bending by more than 10°.

Information 

• Mark the position of all parts in relation to each other before removal. The parts must be re-installed at the same position because otherwise there may be too much imbalance.
• This can damage the mount and cause humming noises.

Information 

• For adequate clearance for the closing tool for the sing le-lug clip on the front joint, push the cardan shaft to the rear.
• Before closing the single-lug clip, check that the cardan shaft is positioned correctly and that the single-lug clip is fitted securely.

1. Position new  single-lug clip -1-  on the cardan shaft.

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   Single-lug clip

2. Install cardan shaft -1-  .

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   Cardan shaft

   1. 2.1  Clean the output shaft splines on the transmission.
   2. 2.2  Push cardan shaft -1-  about 50 millimetres in -direction of arrow A-  onto the splines on the transmission

      Turn the cardan shaft slightly to check whether the splines on the shaft have engaged. 

   3. 2.3  Push cardan shaft -1-  as far as it will go onto the output shaft splines -direction of arrow A-  .
   4. 2.4  Position cardan shaft flange -4-  in -direction of arrow B-  on the rear axle differential.
   5. 2.5  Secure single-lug clip with > V.A.G 1275A-hose clip pliers  .
   6. 2.6  Position centre bearing -3-  and tighten screws -2-  .

      > Tightening - torque 20 Nm (15 ftlb.) 

3. Align rear cardan shaft with the rear axle differential at the previously applied marking. The white dot on the cardan shaft flange may be offset by max. 30° with respect to the green dot on the rear axle differential flange -Arrow-  .

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   Marking installation position of cardan shaft

4. Secure the cardan shaft -2-  to the rear axle differential.

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   Cardan shaft screws

   1. 4.1  Fit cardan shaft on the rear axle differential flange using new  screws and new  plates.

      Information 

      Get another person to help by pressing the brake to prevent the cardan shaft from turning. Alternatively, activate the electronic parking brake (EPB).

5. Tighten cardan shaft screws.
   1. 5.1  Tighten screws using > 9768 - - Electronic torque wrench 2 -100 Nm (1.5 - 74 ftlb.)  in two steps according to the tightening sequence -1 to 6-. 
      Fig 1: Rear Cardan Shaft Screws Tightening Sequence

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      Tightening sequence for rear cardan shaft

      Step 1-Initial tightening:  > Initial tightening 18 Nm 

      Step 2-Threshold torque:  > Initial tightening 50 Nm 

      Step 3-Final tightening torque angle:  > Final tightening + 120° 

   2. 5.2  Immediately after you have tightened each screw to the final tightening torque, mark each one with a felt-tipped pen to be on the safe side.
6. After Installing the cardan shaft, check It by trying to pull it off the transfer gear.
   1. 6.1  To do this, give the front cardan shaft a quick pull to the rear.
7. Install front tunnel support -1-  .

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   Front tunnel support

   1. 7.1  Position the front tunnel support -1-  .
   2. 7.2  Fit and tighten new  screws -2-  .

      > Initial - tightening 60 Nm (44 ftlb.) 

      > Final tightening + 45° 

8. Install tunnel cross member -1-  and heat shield -2-  .

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   Rear tunnel cross member and heat shield

   1. 8.1  Move heat shield -2-  into installation position.
   2. 8.2  Fit and tighten screws -5-  .

      > Tightening - torque 15 Nm (11 ftlb.) 

   3. 8.3  Screw on and tighten nut -5-  .

      > Tightening torque 2 fl.5 ftlb.lNm 

   4. 8.4  Move tunnel cross member -1-  into installation position.
   5. 8.5  Fit and tighten screws -3-  .

      > Tightening - torque 55 Nm (41 ftlb.)