Removing and Installing Rear Cardan Shaft

Removing and installing rear cardan shaft
Tools

Preliminary work for rear cardan shaft

1. Remove exhaust system after catalytic converter.

Removing rear cardan shaft

Note:
^ 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.

Note: 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

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 transmission flange is marked with a white dot, match point, on both components. Match points for cardan shaft to final drive

Note: The color marking, match point, on the cardan shaft and on the rear final drive flange must be aligned. This will neutralize the residual imbalance of the components.

3. Mark the position of the cardan shaft -arrow- with respect to the transfer box flange with a colored pen.

Mark for rear cardan shaft to transfer box

4. Loosen fastening screws -arrow- securing cardan shaft support to centre bearing.

Cardan shaft support to centre bearing

5. Unscrew fastening screws on the cardan shaft at the rear axle transmission ->Cardan shaft to rear final drive. Cardan shaft to rear final drive

ATTENTION: Noises caused by damage in the drive line
-> Faulty centre bearing; replace cardan shaft
-> Do not loosen cardan shaft bolts using rubber/metal disc.

6. Unscrew fastening screws -arrows- on the cardan shaft at the transfer box. Counter with an open-ended wrench.

Cardan shaft to transfer box

ATTENTION: Cardan shaft can be damaged if not handled correctly
-> Avoid repeated sagging or significant vertical traction.
-> When one of the two flanges on the cardan shaft has been released, the centre bearing must be relaxed!
-> Do not leave cardan shaft hanging. All three fastening points for transfer box, centre bearing and rear final drive must always be screwed in.
-> The recommended procedures must be followed during installation, otherwise the position of the cardan shaft in its original place is no longer guaranteed. Possible result: premature failure of the centre bearing resulting in subsequent cardan shaft replacement.

7. Release cardan shaft centre bearing holder. To do this, unscrew six fastening screws -arrows-.

Cardan shaft centre bearing to body

8. Carefully separate cardan shaft from transfer box ->Removing cardan shaft and press backwards.

Removing cardan shaft

Note: To prevent the cardan shaft from being damaged, a second mechanic is required to remove the equipment.

9. Remove the cardan shaft.

Removing rear cardan shaft
1. Move selector lever to position N.

ATTENTION: Cardan shaft can be damaged if not handled correctly
-> Avoid repeated sagging or significant vertical traction.
-> When one of the two flanges on the cardan shaft has been released, the centre bearing must be relaxed!
-> Do not leave cardan shaft hanging. All three fastening points for transfer box, centre bearing and rear final drive must always be screwed in.
-> The recommended procedures must be followed during installation, otherwise the position of the cardan shaft in its original place is no longer guaranteed. Possible result: premature failure of the centre bearing resulting in subsequent cardan shaft replacement.

ATTENTION: Noises caused by damage in the drive line
-> Faulty centre bearing; replace cardan shaft
-> Do not loosen cardan shaft bolts using rubber/metal disc.

Note:
^ 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.

Note: The color marking, match point, on the cardan shaft and on the rear final drive flange must be aligned. This will neutralize the residual imbalance of the components.

2. The position of the cardan shaft -arrows- with respect to the rear axle transmission 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 box flange with a colored pen. Mark for

rear cardan shaft to transfer box

4. Loosen fastening screws -arrows- securing cardan shaft support to centre bearing.

Cardan shaft support to centre bearing

5. Unscrew fastening screws on the cardan shaft at the rear axle transmission. ->Cardan shaft to rear final drive.

Cardan shaft to rear final drive

Note: The damper on the transfer box is removed along with the cardan shaft.

6. Loosen damper at transfer box. To do this, unscrew six fastening screws -arrows-.

Damper to transfer box

7. Unscrew fastening screws -arrows- on the cardan shaft at the transfer box. Counter with an open-ended wrench.

Cardan shaft to transfer box

8. Release cardan shaft centre bearing holder. To do this, unscrew six fastening screws -arrows-.

Cardan shaft centre bearing to body

9. Carefully separate cardan shaft from transfer box and press backwards -arrow-.

Removing cardan shaft

Note: To prevent the cardan shaft from being damaged, a second mechanic is required to remove the equipment.

10. Remove the cardan shaft.

Installing rear cardan shaft

Overview of rear cardan shaft

ATTENTION: Cardan shaft can be damaged if not handled correctly
-> Avoid repeated sagging or significant vertical traction.
-> When one of the two flanges on the cardan shaft has been released, the centre bearing must be relaxed!
-> Do not leave cardan shaft hanging. All three fastening points for transfer box, centre bearing and rear final drive must always be screwed in.
-> The recommended procedures must be followed during installation, otherwise the position of the cardan shaft in its original place is no longer guaranteed. Possible result: premature failure of the centre bearing resulting in subsequent cardan shaft replacement.

ATTENTION: Leakage due to damage to centering sleeve
-> Ensure that no damage occurs during removal and installation.
-> Centering sleeve should be greased slightly.
-> Transfer box journal must be clean.

Note:
^ There is no color 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.

Note: To prevent the cardan shaft from being damaged, a second mechanic is required to install the equipment.

1. Install cardan shaft.
2. Pull cardan shaft joints apart so that they sit in the transmission flanges.

3. Screw in six screws -arrow- on the centre bearing holder but do not tighten.

Cardan shaft centre bearing to body

4. Position the cardan shaft at the color markings -arrow-again.

Marking on transfer box flange/cardan shaft

Note: The color 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

Note:
^ 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.

5. Screw in new screws for cardan shaft flange at the rear axle transmission. Initial tightening 22 ft. lbs. Final tightening 90°

Cardan shaft to rear final drive

6. Tighten bolts connecting cardan shaft triangular flange to transfer box -arrows-. Counter with an open-ended wrench. Tightening torque 56 ft. lbs.

Cardan shaft to transfer box

7. Screw in fastening screws for securing cardan shaft centre bearing holder to body -arrows-. Tightening torque 44 ft. lbs.

Cardan shaft centre bearing to body

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- connecting holder to centre bearing. Tightening torque 15 ft. lbs.

Cardan shaft support to centre bearing

11. Remove special tool centering tool 9680. -arrows-

Removing special tool 9680

Installing rear cardan shaft

Note:
^ Centre bearing must be installed without tension.
^ Fit special tool centering tool 9680 ->Special tool in installation position in the specified sequence.

Special tool in installation position

ATTENTION: Cardan shaft can be damaged if not handled correctly
-> Avoid repeated sagging or significant vertical traction.
-> When one of the two flanges on the cardan shaft has been released, the centre bearing must be relaxed!
-> Do not leave cardan shaft hanging. All three fastening points for transfer box, centre bearing and rear final drive must always be screwed in.
-> The recommended procedures must be followed during installation, otherwise the position of the cardan shaft in its original place is no longer guaranteed. Possible result: premature failure of the centre bearing resulting in subsequent cardan shaft replacement.

ATTENTION: Leakage due to damage to centering sleeve
-> Ensure that no damage occurs during removal and installation.
-> Centering sleeve should be greased slightly.
-> Transfer box journal must be clean.

Note: In vehicles with manual transmission, the damper must be fitted along with the cardan shaft.

Note:
^ There is no color 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 is replaced, the mark you apply is a precautionary measure in order to avoid humming noises from the drive line.

1. Install cardan shaft with damper.
2. Pull cardan shaft joints apart so that they sit in the transmission flanges.

3. Screw in six screws -arrows- on the centre bearing holder but do not tighten.

Cardan shaft centre bearing to body

4. Position the cardan shaft at the color markings -arrows-again.

Marking on transfer box flange/cardan shaft

5. Screw in new screws for cardan shaft flange at the rear axle transmission. ->Cardan shaft to rear final drive Initial tightening 22 ft. lbs. Final tightening 90°

Cardan shaft to rear final drive

6. Secure damper on transfer box. To do this, screw in six fastening screws -arrows-. Tightening torque 24 ft. lbs.

Damper to transfer box

7. Tighten bolts securing the cardan shaft triangular flange to transfer box -arrows- Tightening torque 56 ft. lbs.. Counter with open-ended wrench.

Cardan shaft to transfer box

8. Screw in fastening screws -arrows- for securing cardan shaft centre bearing holder to body. Tightening torque 44 ft. lbs.

Cardan shaft centre bearing to body

9. Mount special tool centering tool 9680.

Mounting special tool 9680

10. Press on special tool centering tool 9680 in sequence according to numbering -1,2-.

Pressing on special tool 9680

11. Tighten bolts -arrows- securing holder to centre bearing. Tightening torque 15 ft. lbs.
Cardan shaft support to centre bearing

12. Remove special tool centering tool 9680. -arrows-
Removing special tool 9680

Subsequent work - rear cardan shaft
1. Install the exhaust system.