Intermediate Shaft

To remove
1. Disconnect the negative battery cable.





2. Place covers over the wings and lift out the cover over the intake manifold.
3. Remove the stay between the suspension strut towers (RHD only).





4. Use a 1/2" flexible handle to relieve the strain on the belt tensions
5. Remove the belt tensioner, using an 8 mm Allen key.
6. Remove the generator upper screw using an 8 mm Allen key.
7. Raise the car.
8. Remove the right-hand wheel.





9. Remove the belt circuit cover.
10. B235R: Detach the brake caliper and suspend it.
11. Undo the nuts securing the anti-roll bar and the wishbone's ball joint. Use puller 89 96 696.
12. Lower the suspension arm and fix it in position with a block of wood inserted between the arm and anti-roll bar.
13. Undo the clamp and pull away the boot.
B235R: Tap the drive shaft out of the intermediate shaft using a brass drift/hammer.
14. Swing the wheel to the left to make it easier to remove the drive shaft.
B235R: Tap out the drive shaft even further if necessary.
Grasp the MacPherson stout and pull. The drive shaft will then come away with it. Then lower the drive shaft in front of the suspension arm.

IMPORTANT: It is essential that dirt is not allowed into the universal joint. Cover the universal joint and drive plate with plastic bags, for example.





15. Disconnect the generator cables and the generator bracket lower bolt.
16. Move the generator aside.
17. Unscrew the support bearing bracket bolts.

IMPORTANT: Place a receptacle under the gearbox to avoid spilling oil on floor.

18. Pull the support bearing bracket away from the guide pins in the engine block and withdraw the intermediate shaft from the gearbox.

To fit





1. Fit Protective collar 83 95 162 to the sealing ring.

IMPORTANT: Always replace the shaft seal in the gearbox. Lubricate with transmission fluid.

2. Make sure that the intermediate shaft is clean and then fit the shaft in the tool.

IMPORTANT: Insert the intermediate shaft in the gearbox until about 20 mm of it remains and withdraw the tool before the shaft sealing surface reaches the shaft seal.

3. Insert the remainder of the shaft.
4. First guide the support bearing bracket to the upper guide pin and then tighten the bearing bracket.
Tightening torque: 24 Nm (18 ft. lbs.)





5. Make sure that the adjusting sleeves are tapped out about 1 mm to facilitate fitting the generator on the mountings. Then fit the two generator retaining bolts and tighten the lower one.
Tightening torque: 47 Nm (35 ft. lbs.)
6. Connect the generator cables.
7. Fill the boot and drive plate with grease, (16) 87 92 624, and attach the universal joint to the drive plate. Fit a new clamp to the boot and wipe off excess grease.
B235R: Swing out the suspension strut and attach the drive shaft to the intermediate shaft until the circlip snaps in place. Lubricate with universal paste 87 81 684.
8. Remove the wooden block, swing the suspension arm back and connect it to the steering swivel member. Fit the bolt and tighten it.
Tightening torque: 75 Nm (55 ft. lbs.)
9. Tighten the anti-roll bar
10. B235R: Fit the brake caliper. Apply Loctite 242, part no. (16) 74 96 268, to the bolts.
Tightening torque 110 Nm (81 ft. lbs.)
11. Lower the car to the floor.





12. Tighten the generator upper bolt.
Tightening torque: 47 Nm (35 ft. lbs.)
13. Fit the belt tensioner.
14. Fit the belt.
15. Fit the stay between the suspension strut towers and press on the protective cover (RHD only).
Tightening torque: 24 Nm (18 ft. lbs.)





16. Press the cover over the intake manifold into place.
17. Connect the negative lead to the battery.
18. Fill up with automatic transmission fluid to the correct level.





19. Raise the car and fit the cover over the belt circuit.
20. Fit the wheel.
Tightening torque: 110 Nm (81 ft. lbs.)

IMPORTANT: The wheel should hang freely when the wheel bolts are tightened.

21. Lower the car to the floor.
22. Set the clock and radio code if applicable