Axle Shaft Assembly: Service and Repair

Removing and Installing Rear Drive Shaft (Manual Transmission)




Tools


Removing




Removal illustration, steps 1 - 5

NOTE:





Since the drive shaft can be moved only using great force, loosen the shaft inwards with taps on a copper mandrel. For unfavourable tolerances, the drive shaft must be pressed out of the toothing using a universal wheel-hub extractor. See step 9 also.


1 - Lift the vehicle. Remove the wheel and undo axle nut -arrow- Actuate the foot brake and parking brake for this purpose.

2 - Push the protection -arrow- over the drive shaft.

3 - Undo the drive shaft on the transmission flange.

4 - Unscrew the lower linkage for the headlight height adjustment -arrow- (counter with open-ended wrench). Only on left side.

5 - Loosen stabilizer mount -arrow- at stabilizer (counter with open-ended wrench).

Removal illustration, steps 6 - 10

6 - Remove the lower fastening screw of the spring strut -arrow-.

7 - Undo the nut on the tie rod end (if necessary counter with Torx screwdriver 9546). Press the tie rod end off with a press-out tool 9560.

8 - Disengage the parking brake cable at the parking brake lever. To do this, remove the floor of the oddments tray in the centre console. Undo the 2 M8 nuts -1-. Remove the tab washer -3- from the retaining lug -4- with a screwdriver. Take the corresponding parking brake cable out of the guide.

9 - Press the wear indicator/speed sensor wire out of the holder. Undo both upper axle struts and remove the screws. Press the drive shaft out, if necessary (given unfavourable tolerances) with a wheel-hub extractor.

10 - Swivel the wheel carrier outwards until there is enough space for the drive shaft to be extended. A second fitter is required.


Installation





Installation illustration, steps 1 - 5

CAUTION:
Danger of injury and material damage it the wheel carrier is raised incorrectly.
- Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When raising, use a suitable intermediate layer (hard rubber).
- Do not damage the brake cover plate.

NOTE:
- Carry out a visual inspection of all parts.
- Grease the drive shaft toothing with Optimoly HT.
- Replace self-locking nuts.





- The entire threaded parts of the axle must be tightened in vehicle position. Vehicle position means: vehicle standing on the wheels, or the wheel suspension is being raised with a universal vehicle lift. Use an intermediate layer (hard rubber). Do not damage the brake cover plate.
- Use correct tightening torques.
- It is not necessary to calibrate the sensor for headlight beam adjustment (only left vehicle side.).


1 - Swivel the wheel carrier outwards until there is enough space for the drive shaft to be inserted. 2. A second fitter is required.

2 - Fit both axle struts -arrows- on the wheel carrier. Insert wear indicator/speed sensor wire in the holder.

3 - Engage the inside parking brake cable (reverse procedure to that described in Point 8 Removal).

NOTE: When inserting the parking brake cable into the guide tube of the body, always make sure that the sleeve of the parking brake cable is pushed fully onto the guide tube. Otherwise, correct adjustment of the parking brake will not be possible.

4 - Mount the tie rod end on the wheel carrier.

5 - Insert the fastening screw of the lower spring strut -arrow-.

Installation illustration, steps 6 - 10

6 - Screw on the stabilizer mount -arrow-. Counter with an open-ended wrench when doing this.

7 - Screw on the lower linkage for the headlight height adjustment -arrow- (counter with open-ended wrench). Only on left side.

8 - Mount the drive shaft on the transmission flange.

9 - Remove the drive shaft protection -arrow-.

10 - Tighten axle nut -arrow-. Fasten the wheel.