Axle Shaft: Service and Repair

To Remove





1. Lift off the battery cover.
2. Remove the negative lead from the battery.





3. Lay down wing protectors and lift away the cover over the intake manifold.
4. Relieve the belt tensioner with tool 83 95 25 and lift off the multigroove belt
5. Remove the belt tensioner using an 8 mm allen key.
6. Remove the upper generator bolt with an 8 mm allen key
7. Raise the car.
8. Remove the RH wheel.





9. Remove the cover on the belt circuit.





10. Undo the clips for the brake hoses and bend the hose to one side. Undo the ABS cable
11. Remove the outer suspension arm through bolt from the steering swivel member.
12. Tap loose the drive shaft from the intermediate shaft with a brass drift/hammer.
13. Pry loose and lower the suspension arm and secure it in this position with a block of wood between the suspension arm and the anti-roll bar.
14. Turn the wheel to the left for better access to the drive shaft. Knock the drive shaft further out if necessary. Grip the MacPherson strut and pull. The drive shaft will then come with it. Then let it tilt down in front of the suspension arm.





15. Remove the generator cables and the lower generator bracket bolt.
16. Move the generator out of the way.





17. Unscrew the support bearing bracket screws.

IMPORTANT: Place a vessel under the gearbox to avoid oil spill on the floor.

18. Fold out the support bearing bracket from the guide pins in the engine block and extract the intermediate shaft from the gearbox.

To Fit





1. Fit protective collar 83 95 162 in the sealing ring.

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

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

IMPORTANT: Fit the intermediate shaft in the gearbox until about 20 mm remains and extract the tool before the shaft's sealing surface reaches the shaft seal.

3. Push in the rest of the shaft.
4. Guide the support bearing bracket to the upper guide pin first and then tighten the support bearing bracket.





5. Make sure the adjuster sleeves are projecting approx. 1 mm to make it easier to fit the generator to the mounting. Then fit both the generator bolts and tighten the lower one.
6. Connect the generator cables.





7. Tilt out the MacPherson strut and attach the drive shaft to the intermediate shaft until the circlip snaps in place. Lubricate with, universal paste, part no. 87 81 684.
8. Remove the block of wood, replace the suspension arm and attach it to the steering swivel member. Fit and tighten the bolts
Tightening torque 100 Nm (74 ft. lbs.)

WARNING: Make sure the steering link pin is visible on top of the steering swivel member before fitting the bolt.

9. Secure the brake hose to the mounting on the steering swivel member and fit the clips. Fit the ABS cable. (2 mountings)





10. Fit the cover for the belt circuit.
11. Fit the wheel.
Tightening torque 110 Nm (80 ft. lbs.)

IMPORTANT: The wheel must be suspended freely when tightening the wheel bolt

12. Lower the car to the floor.





13. Tighten the upper generator bolt.
14. Fit the belt tensioner.
15. Fit the pulley.





16. Press on the cover over the intake manifold.
17. Connect the negative lead to the battery and fit the battery cove
18. Fill up with automatic transmission fluid to the correct level.
19. Set the clock and radio code if applicable.