Differential Output Shaft: Service and Repair

Removing and installing cardan flange








Preliminary work

Danger:
Vehicle raised incorrectly.
^ Danger of fatal injury or material damage should the vehicle fall down.

- Raise the vehicle at the prescribed jacking points.

1. Jack and raise the vehicle at the prescribed jacking points.
2. Remove underbody panelling.

Removing cardan flange

1. Move gear selector to "P" and firmly apply the handbrake.
2. Remove the cardan flange.
2.1. Loosen and screw off the collar nut -2- with a socket (a/f 36).





Removing cardan flange

2.2. Remove cardan flange -1- using three-arm puller: span width 100 mm, span depth 100 mm NR.112-1 and pressure piece 9790 to pull it off the pinion shaft -2-.





Pulling off cardan flange

Information:
The cardan flange is connected to the pinion shaft of the Porsche Doppelkupplung with very tight tolerances, i.e. increased removal and installation forces must be overcome when removing and installing the cardan flange. Make sure that the tool is perfectly aligned so as to eliminate the possibility of warping and prevent the tool from slipping off.

Installing cardan flange

1. Install cardan flange.
1.1. Degrease the pinion shaft journal (splines and thread), halfshaft flange splines and thread of the collar nut with cleaning agent (e.g. Loctite quick cleaner).
1.2. Heat cardan flange to approx. 120°C.
1.3. Position cardan flange -1- on the splines and drive it in using socket-wrench insert Nr.64 until the cardan flange -1- is flush.





Installing cardan flange

Information:
The cardan flange is connected to the pinion shaft of the Porsche Doppelkupplung with very tight tolerances, i.e. increased removal and installation forces must be overcome when removing and installing the cardan flange. Make sure that the tool is perfectly aligned so as to eliminate the possibility of warping and prevent the tool from slipping off.

1.4. Replace and tighten the collar nut.





Subsequent work

1. Install cardan shaft.
2. Check and if necessary, top up the ATF.
3. Fit underbody panelling.
4. Lower the vehicle.