Right Side Rear Drive Shaft
NOTE:
With regard to rear drive shaft removal and installation, there are considerable differences in the configuration between transmission types and the sides of the vehicle. Separate procedures are therefore given.
Removing And Installing Right Drive Shaft
1. Remove rear wheel, engine guard from engine/transmission and rear underside panel.
2. Loosen drive shaft from wheel.
- When doing so, also apply the brakes.
NOTE:
- As considerable force is needed to move the drive shaft in the teeth of the wheel hub, loosen the drive shaft using a copper drift.
- With unfavorable tolerances, it may be necessary to push the drive shaft out of the hub using a wheel hub puller (e.g. a Klann or Schrem tool).
- On the 911 Turbo, a ventilation tube is inserted in the joint on the wheel.
- To prevent damage to the ventilation pipe when pressing the drive shaft out of the wheel hub, insert a pressure piece, e.g. VW 295A, between the puller spindle and the drive shaft.
- At this stage, it is not yet possible to pull the drive shaft out completely.
3. Remove cover from control arm 1 & 5 (unclip).
- Remove heating pipe (No. 1).
4. Release fastening screws of connector unit/grounding cable and speed sensor from wheel carrier (arrow).
- Unclip lines from wheel carrier (No. 1) and parking brake cable.
- Remove speed sensor.
5. Remove brake caliper from wheel carrier and hang it up in wheel arch.
6. Disconnect stabilizer mount from stabilizer (holding open jaw wrench against bolt).
- Remove stabilizer clamp.
NOTE:
- The stabilizer mount must remain attached to the spring strut.
- The stabilizer must not be removed.
7. Dismantle parking brake cable as follows:
- Remove cassette box and trim panel above parking brake lever.
- Loosen and completely unscrew lock nut and adjustment nut (No. 1) from arm (No. 2).
- Remove safety clip (No. 3) from support pin (No. 4) of parking brake lever and remove support pin.
- Remove parking brake lever (with arm)
- Unhook tab washer (No. 5) for parking brake cables from retaining lug (No. 6) - at top and bottom.
- Unhook appropriate parking brake cable and pull it out of the guide from the back.
8. Remove control arm 2 (toe control arm).
CAUTION:
- Before loosening the bolts, mark the position of eccentric bolt A for installation, so that a complete measurement of vehicle alignment is not necessary.
- When loosening the ball joint, hold a Torx screwdriver (special tool 9546) against the wheel carrier.
NOTE: If necessary for removing control arm 2 from the wheel carrier/spring strut eye, lift the wheel carrier slightly using a universal jack.
9. Disconnect control arm 1 & 5 from subframe (internal connection / 2 screws).
10. Unscrew pan head screws of drive shaft from transmission flange.
NOTE: To prevent damage to the drive shaft, place a protective tube on the drive shaft.
11. Mount a suitable lever on the wheel hub.
- Using the lever, lift the wheel carrier and swing it out at the bottom.
- Pull out the drive shaft in this position (2nd mechanic required).
- Depending on tolerances, it may also be necessary to turn the wheel carrier in the direction of toe-in with the lever.
Installation Right Drive Shaft
1. To install the drive shaft, proceed in reverse order.
- Carry out a visual inspection of all parts before starting installation.
- Grease the drive shaft teeth with Optimoly HT.
- First step: Insert the drive shaft.
2. Check thread condition and grade of eccentric bolt.
- Required grade 10.9 (grade first used 8.8 check spare parts catalog).
- The grade is shown on the bolt head.
- If thread is damaged or bolt is grade 8.8, use new eccentric bolt.
- In this case, transfer position mark from old eccentric bolt to new bolt.
3. Do not grease Dacromet bolting (aluminum appearance).
- Observe torque specifications.
CAUTION: Before tightening bolts on subframe, see step 4 below.
4. Tighten bolts in area A (eccentric bolt) and bolt of control arm 5 once reference position has been established.
- Reference position = Control arm 2 and the rear cross member must form a horizontal line.
- To establish reference position, lift wheel carrier with universal jack.
NOTE: The bolts mentioned above can also be tightened when the vehicle is on its wheels and has been pushed up and down about 25 mm a few times.
5. Install parking brake cable and adjust parking brake.
- Install brake caliper.
6. Tighten drive shaft on transmission flange and wheel hub.
- Use new fastening nut.
7. Install cover of control arm 1 & 5 and the underside guards and panels.
NOTE: If drive shafts are installed and removed in accordance with these instructions, alignment measurements are not necessary as there are only minor changes in wheel alignment. The max. change in toe-in per rear wheel is 5'.