Removing and Installing Rear Cardan Shaft
Removing and installing rear cardan shaft
Preliminary work for rear cardan shaft
Preliminary work - rear cardan shaft
1. Remove exhaust system after catalytic converter.
Removing rear cardan shaft
Notice
Incorrect handling of cardan shaft
^ Risk of damage to the cardan shaft
^ Risk of damage to the center bearing
^ Humming noises caused by defective center bearing
-> When one of the two flanges on the cardan shaft has been released, relieve the tension on the center bearing.
-> Do not leave cardan shaft hanging. Always screw in all three fastening points for transfer gear, center bearing and rear final drive.
-> Follow the recommended procedures during installation, otherwise the position of the cardan shaft in its original place is no longer guaranteed.
Information
^ The colour marking, match point -arrow-, on the cardan shaft and on the flange of the rear final drive must be aligned. This will neutralize the residual imbalance of the components.
Match points for cardan shaft to final drive
Information
^ If the cardan shaft or transfer box has to be replaced, please ignore the next step.
^ Marking the position of the cardan shaft with respect to the transfer box triangular flange serves only to prevent possible humming noises.
Information
^ To prevent the cardan shaft from being damaged, a second mechanic is required to remove the equipment.
Overview of cardan shaft
1. Move selector lever to position N.
2. The position of the cardan shaft -arrows- with respect to the rear axle differential flange is marked with a white dot - match point - on both components.
Match points for cardan shaft to final drive
3. Mark the position of the cardan shaft -arrow- with respect to the transfer gear flange with a colored pen.
Mark for rear cardan shaft to transfer gear
4. Loosen fastening screws -arrow- securing cardan shaft support to center bearing.
Cardan shaft support to center bearing
Notice
Incorrect tools used for removing components
^ Risk of damage to components
-> Do not use tools, such as a hammer or similar object.
-> Spray components with anti-rust agent before removing them.
Information
^ To loosen the cardan shaft on the rear axle transmission, a second fitter should counter the fastening screws -arrows- at the triangular flange of the transfer box.
Rear cardan shaft to transfer box
5. Unscrew fastening screws on the cardan shaft at the rear axle differential.
Cardan shaft to rear final drive
Information
^ The screws securing the flexible disc to the cardan shaft must not be loosened.
6. Unscrew fastening screws -arrows- used to secure the cardan shaft to the transfer gear. Counter with an open-ended wrench.
Cardan shaft to transfer gear
7. Release cardan shaft center bearing holder. To do this, unscrew six fastening screws -arrows-.
Cardan shaft center bearing to body
8. Carefully separate cardan shaft from transfer gear and press backwards.
Removing cardan shaft
9. Remove cardan shaft.
Installing rear cardan shaft
Notice
Incorrect handling of cardan shaft
^ Risk of damage to the cardan shaft
^ Risk of damage to the center bearing
^ Humming noises caused by defective center bearing
-> When one of the two flanges on the cardan shaft has been released, relieve the tension on the center bearing.
-> Do not leave cardan shaft hanging. Always screw in all three fastening points for transfer gear, center bearing and rear final drive.
-> Follow the recommended procedures during installation, otherwise the position of the cardan shaft in its original place is no longer guaranteed.
Notice
Damaged dowel sleeve
^ Leaks
-> Carefully remove and install the dowel sleeve.
-> Grease the dowel sleeve slightly during installation.
-> Transfer gear journal must be clean.
Information
^ To prevent the cardan shaft from being damaged, a second mechanic is required to install the equipment.
Information
^ There is no colour marking on the flange to the transfer box for installing new components, transfer box or cardan shaft. As a result, positioning is not an issue.
^ If none of the components are replaced, the mark you apply is a precautionary measure in order to avoid humming noises from the drive line.
Information
^ To attach the cardan shaft to the rear axle transmission, a second fitter should counter the fastening screws on the triangular flange of the transfer box.
^ Screws which are tightened with a torque angle must be replaced with new ones.
Overview of rear cardan shaft
1. Install cardan shaft.
2. Pull cardan shaft joints apart so that they sit in the transmission flanges.
3. Position six new screws -arrow- on the center bearing holder but do not tighten.
Cardan shaft center bearing to body
4. Position the cardan shaft at the colour markings -arrow- again.
Marking on transfer gear flange/cardan shaft
Information
^ The colour marking, match point -arrow-, on the cardan shaft and on the flange of the rear final drive must be aligned. This will neutralize the residual imbalance of the components.
Match points for cardan shaft to final drive
5. Tighten new screws for cardan shaft flange on the rear axle differential. -> Initial tightening: 30 Nm (22 ftlb.) -> Final tightening: 90°
Cardan shaft to rear final drive
6. Tighten bolts connecting cardan shaft triangular flange to transfer gear -arrows-. Counter with an open-ended wrench. -> Tightening torque: 75 Nm (56 ftlb.)
Cardan shaft to transfer gear
7. New fastening screws must be used to secure the cardan shaft center bearing holder to the body -arrows-. -> Tightening torque: 60 Nm (44 ftlb.)
Cardan shaft center bearing to body
Information
^ center bearing must be installed without tension.
^ Fit special tool centering tool 9680 in the specified sequence.
Special tool in installation position
8. Mount special tool centering tool 9680 -arrow, inset-.
Mounting special tool 9680
9. Press on special tool centering tool 9680 in sequence according to numbering -1, 2-.
Pressing on special tool 9680
10. Tighten bolts -arrow- securing holder to center bearing. -> Tightening torque: 20 Nm (15 ftlb.)
Cardan shaft support to center bearing
11. Remove special tool centering tool 9680. -arrows-
Removing special tool 9680
Subsequent work
Subsequent work - rear cardan shaft
1. Install the exhaust system.