Front Propellar Joint, Replacing

Front propeller joint, replacing

Special tools:
999 5427
999 5743

Removal
Removing the rear joint from the propeller shaft

Mark the position of the propeller shaft flange in relation to the flange on the torque tube.

Note! Carefully note the length and position of screws on the propeller shaft constant velocity joint. Also see Specifications .

Remove the propeller shaft screws. Use counterhold 999 5743

Note! Wrong counterhold illustrated.

Removing the front joint on the propeller shaft



Remove the propeller shaft screws. Use counterhold 999 5743



Note! Wrong counterhold illustrated

Remove:



- the 2 screws (2) holding the propeller shaft to the SIPS member
- the 4 screws (1) for the SIPS member one at a time. Screw them in again 4 turns
- the propeller shaft.

Place the propeller shaft in a vice. Use pieces of wood.

Note! The propeller shaft must be replaced if it is damaged.

Removing the propeller joint



- Tap off the front cover using a screwdriver and a hammer.
- Wipe off the grease.



- Remove the snap ring.



- Remove the clamp (1) from the rubber boot.



- Remove the propeller joint from the propeller shaft. Use puller 999 5427 or knock it off using a plastic mallet.

Note! The propeller shaft must be replaced if it is damaged.



- Wipe any grease and dirt off the propeller shaft and splines.

Installation
Installing the propeller joint



- Squeeze grease into the joint on the surface (2).

Note! There must not be any grease on the mating surface (1).

- Apply a thin layer of liquid gasket to the mating surfaces (1) on both the joint and the rear cover.
- Install the rear cover on the propeller shaft. Ensure that the holes are aligned.

- Install:
- the propeller joint on the propeller shaft. Knock it into place using a rubber mallet. Use a socket as a spacer for the last bit.



- the snap ring. Check that it is in the groove.




- Squeeze the remaining grease into the propeller joint (2). The entire contents of the tube must be used.

Note! There must not be any grease on the mating surface (1).

- Install the gasket and the front cover by hand. Ensure that the holes are aligned.
- Press the cover onto the propeller joint, using 2 washers, 4 screws and 4 nuts. Tighten crosswise until the cover bottoms on the joint.



- Remove the screws, nuts and washers.
- Press the air out of the rubber bellow. Ensure that the rubber boot is positioned correctly on the propeller shaft.



- Install the new clamp (1).

Installing the propeller shaft



- Install:
- the propeller shaft in the car
- the 2 screws (2). Tighten to 25 Nm.
- Tighten the 2 screws (1). Tighten to 25 Nm.
- Check that the viscous coupling and propeller shaft flange mating surfaces are clean.
- Install the propeller shaft as marked.
- Use new screws of the same length. Reinstall the screws in the same positions.



- First tighten the screws crosswise. Tighten to 8 Nm. Then re-tighten crosswise. Tighten to 30 Nm. Use counterhold 999 5743 .
Note! Wrong counterhold illustrated.

- Start tightening with the same screw both times.
- Check that the bevel gear and propeller shaft flange mating surfaces are clean.
- Use new screws.



- First tighten the screws crosswise. Tighten to 8 Nm. Then re-tighten crosswise. Tighten to 30 Nm. Use counterhold 999 5743

Note! Wrong counterhold illustrated.

- Start tightening with the same screw both times.