Rear Suspension

Removing and installing rear axle housing
These removal and installation instructions apply to vehicles with level control and steel springs. The points relating to level control are not relevant for vehicles with steel springs.





Tools

Removal

Caution! Risk of damage to property and personal injury when working on the exhaust system, the rear axle and the vibration dampers. Wear protective gear, e.g. gloves.
Position the mounting frame correctly on the lifting platform and carefully remove the rear axle housing.
Watch out for falling parts during removal on the mounting frame.

1. In vehicles with level control: Switch off level control.





2. To bleed the level control (air pressure must be allowed to escape out of system), use the Porsche System Tester. To do this, select the Bleed level control menu item in the Level control system.
3. Raise the vehicle at the support points provided for this purpose.
4. Remove the rear wheels.
5. Remove the exhaust silencer.





6. Remove the combination wires at the joint (brake wear, CDC sensor) -1- and then unclip the rubber sleeves -2- from the sheetmetal holders.
7. Undo the brake caliper and hang it in a suitable place in the wheel well.

Note!
^ Always wear safety goggles and gloves when working on vehicles with level control.
^ Mark the installation position (e.g. with a felt-tip pen) when removing the cardan shaft.
^ Mark the installation position (e.g. with a felt-tip pen) when removing the rear axle housing.
^ The mounting points 11 and 22 are required for removing the rear axle. Remove the remaining mounting points.





8. In vehicles with level control, disconnect the -air connection to the spring struts (arrow)- (front axle connection shown here).
9. Remove the bleeder line from the rear axle transmission.
10. Unclip both brake cables from the Quickfit attachment and remove them from the cable guides. Hang the cables in a suitable place to prevent damage.





11. Mark the -installation position of the cardan shaft (arrow)-.





12. Make sure that the cardan shaft does not become kinked (tie it up, ).





13. Disconnect the plug connections for level control and headlight beam adjustment. On vehicles with differential lock, disconnect the plug connection on the rear axle transmission.





14. For installation, it is a good idea to mark the installation position of the rear axle housing diagonally at at least two places on the body. To do this, place the marks vertically with respect to the floor of the body using a felt-tip pen (e.g. mark along the rear axle housing mount with the pen).





15. Position the -mounting frame- correctly on the lifting platform.





16. Position the lifting platform with the mounting frame under the rear axle housing.





17. Push into the -mounting points (arrows)- provided for this purpose. The show the mounting points for the mounting frame in the rear axle housing.





18. Remove the attachments on the damper housing.





19. Loosen the rear axle housing. Lower the rear axle while taking care not to damage adjacent components.
Subsequent work can be carried out on the mounting frame.
20. Remove the stabilizer on the vibration dampers and on the rear axle housing.
21. Detach the halfshafts at the rear axle transmission.

Note!
^ Get a second worker to help to remove the wheel carrier with accessories and the rear axle transmission.

22. Remove the damper housing.
23. Loosen the triangular control arms, control arms and tie rods on the rear axle housing. Remove the wheel carriers with triangular control arms, control arms, tie rods and halfshafts.
24. Remove the rear axle transmission by unscrewing the screws on the rear axle housing and lifting out the transmission.

Installation

Caution! Risk of damage to property and personal injury (crushing, cuts) when working or/ the exhaust system, rear axle and vibration/ dampers. Wear protective gear, e.g. gloves and safety goggles.
When filling the air spring struts, the vehicle lifts..
Danger of injury and material damage if the wheel carrier is raised incorrectly.
^ Do not raise the wheel suspension higher than the Formal vehicle position (vehicle resting on wheels). When raising the suspension, use a suitable intermediate layer (hard rubber).
^ Do not damage the brake cover plate.
^ The steering angle sensor must be calibrated following repairs.
^ Watch out for falling parts during installation on the mounting frame.

Note!
^ Before installing the rear axle frame, check the parts visually.
^ Position the rear axle housing at the previously-applied markings on the body.
^ Position the cardan shaft at the previously-applied markings.
^ Replace all fastening nuts and all expansion screws (screws which are fitted with torque angle tightening procedure).





^ 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 raised using a universal vehicle lift. -Dimension X-, from lower edge of wing to middle of axle 506 mm ± 10 mm corresponds to vehicle position.
^ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When raising the suspension, use a suitable intermediate layer (hard rubber).
^ Use correct tightening torques.
^ The suspension must be aligned following repair work.





^ Calibrate the steering angle sensor with the Porsche System Tester.
^ Calibrate level control with the Porsche System Tester.
^ Perform a function test.

Install in reverse order.
1. Position the rear axle housing on the mounting frame.
2. Pre-fit the accessories on the rear axle housing. Get another worker to help. A final tightening of the screw connections must be performed when the vehicle is in normal vehicle position.





3. Position the rear axle housing and damper housing back in the original, marked installation position and tighten; be careful not to damage adjacent parts.
4. Fit the halfshafts, stabilizer, plug connections and the bleeding line on the rear axle transmission.
5. Fit the cardan shaft, brake cables, brake calipers and combination connectors. Follow correct cable routing.
6. On vehicles with level control, attach the air connection to the spring struts.
7. Fit the exhaust silencer.
8. Mount the wheels.
9. To fill the level control system, use the Porsche System Tester. To do this, select the Fill air suspension menu item in the Level control system. Switch on level control.
10. Perform suspension alignment.