Removing and Installing Sealing Ring For Long Halfshaft Flange
Removing and installing sealing ring for long halfshaft flange
Preliminary work
Danger
Vehicle raised incorrectly
Danger of fatal injury and material damage should the vehicle fall down
- Jack the vehicle at the prescribed jacking points.
1. Jack and raise the vehicle at the prescribed jacking points.
Information
Take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points.
2. Remove left rear wheel.
Removing sealing ring for long halfshaft flange
Removing long halfshaft flange
Information
Protect drive shafts against mechanical damage (e.g. with a rubber hose that has been cut open).
1. Remove support plate.
Support plate
1.1. Remove diagonal braces.
Unscrew M10/M12 screws and M10 nuts and remove diagonal braces -1-.
1.2. Remove support plate.
Unscrew M10 x 25 screws and M10 nuts and remove support plate -2-.
2. Remove cross member.
Transverse strut
Unscrew M10 x 70 screws -1- and remove cross member -2-.
3. Remove drive shafts on the transmission side.
3.1. Counter using special tool adapter plate 9510/1 (-1-).
Retaining tool for drive-shaft bolts
3.2. Unscrew the six bolts between the drive shaft and transmission flange.
Information
The sealing ring for the long halfshaft flange cannot be replaced while the long halfshaft flange is still installed. In the event of leaks, the sealing ring must always be replaced together with the mounting saddle.
Drive shaft
4. Remove anti-roll bar on rear-axle carrier side section.
Anti-roll bar
Unscrew M8 x 40 screws -1- and move anti-roll bar -2- into position.
5. Support the engine and lower the transmission.
5.1. Retainer plate 9769 (-1-) must be secured on the unit lifting platform using an M10 screw.
Engine mounting
Engine with unit lifting platform
5.2. Position unit lifting platform -1- under the vehicle, insert the mounting pegs of the retainer plate 9769 -2- into the mounting bores on the engine and press in with a slight preload. The unit lifting platform -1- must be positioned slightly diagonally -3- using the adjustment controls so that the bores are directly parallel.
- Adjustment value: 10 degrees
5.3. Remove left and right gear support and hydraulic mount.
Transmission support
C - Nut (never loosen)
5.3.1. Information: Do not loosen nuts -C-.
Gear support
5.3.2. Unscrew screws -2- on the transmission supports -3-.
5.3.3. Unscrew M8 nuts -1- between the body and hydraulic mount and remove transmission support with hydraulic mount -3-.
5.4. Lower the transmission.
Only lower the transmission sufficiently to allow access to the cable connections and coolant hoses.
6. Disconnect coolant hoses at the ATF cooler.
Coolant hoses at ATF cooler
6.1. Clamp coolant hoses.
6.2. Disconnect coolant hoses -1- by releasing the spring band clamps -2- using a pair of angled spring band pliers -3- and pull off coolant hoses -1-.
7. Remove ATF lines and ATF cooler on the transmission.
Holder for ATF lines
7.1. Loosen and unscrew screw -2- for clamping holder -1- on the Porsche Doppelkupplung and remove clamping holder -1-.
7.2. Pull ATF lines -3- out of the Porsche Doppelkupplung.
ATF cooler
7.3. Detach ATF cooler and press upwards.
Loosen and unscrew M6 x 12 screw -1- and press ATF cooler -2- upwards.
8. Remove mounting saddle using a long halfshaft flange.
Long halfshaft flange
8.1. Loosen and unscrew screws -1 to 5-.
8.2. Drive out long halfshaft flange -1- using striking tool VW 771/1 (-2-).
Long halfshaft flange
8.3. Remove the mounting saddle -2- using a long halfshaft flange -1-.
Long halfshaft flange
Installing sealing ring for long halfshaft flange
Installing long halfshaft flange
Information
The aluminium screws on the Porsche Doppelkupplung must be tightened according to a yield strength-controlled tightening procedure using an electronic torque wrench 9768.
To ensure that the screws are tightened uniformly, the corresponding tightening setting "light, medium or hard" must always be used.
1. Replace sealing ring for long halfshaft flange.
Long halfshaft flange
Always replace seal -2-.
Information
The sealing ring for the long halfshaft flange cannot be replaced while the long halfshaft flange is still installed. In the event of leaks, the sealing ring must always be replaced together with the mounting saddle.
2. Install mounting saddle using a long halfshaft flange.
2.1. Fit the mounting saddle using a long halfshaft flange.
2.1.1. Check halfshaft flange for burrs and sharp edges on the transmission end of the shaft -arrow- and deburr if necessary.
Checking halfshaft flange
2.1.2. Fit the mounting saddle -2- using a long halfshaft flange -1-.
Long halfshaft flange
2.2. Tighten the mounting saddle.
Long halfshaft flange
Fit mounting saddle and screw in screws. Use an electronic torque wrench 9768 to tighten the screws in the sequence -1 to 5-.
Always use new aluminium screws. Blow out threaded bore thoroughly with compressed air.
Tighten M8 screws at "medium" setting.
- Tightening torque: 6 Nm (4.5 ftlb.)
2.3. Drive in long drive shaft flange by tapping lightly with a hammer (rubber hammer).
ATF cooler
3. Fit ATF cooler.
3.1. Screw in and tighten screws -1-.
Always use new aluminium screws. Blow out threaded bore thoroughly with compressed air.
Tighten M6 screws at "medium" setting.
- Tightening torque: 2.4 Nm (2 ftlb.)
4. Fit ATF lines on transmission.
Holder for ATF lines
4.1. Press ATF lines -3- into the Porsche Doppelkupplung.
4.2. Fit clamping holder -1- and screw in and tighten screw -2- on the Porsche Doppelkupplung using an electronic torque wrench 9768.
Always use new aluminium screws. Blow out threaded bore thoroughly with compressed air.
Tighten M8 screws at "medium" setting.
- Tightening torque: 6 Nm (4.5 ftlb.)
5. Connect coolant hoses at the ATF cooler.
Coolant hoses at ATF cooler
5.1. Connect coolant hoses -1- by releasing the spring band clamps -2- using a pair of angled spring band pliers 3- and securing them on the coolant hoses -1-.
5.2. Remove hose clamps.
6. Install transmission holder.
6.1. Raise the transmission.
Hydraulic garage jack H 2 SL WE 1032
6.2. Install left and right gear support and hydraulic mount.
Gear support
Fit gear support -3- and hydraulic mount. Screw on and tighten M8 nuts -1- on hydraulic mounts and M10 screws -2- on gear support -3-.
M10
- Tightening torque: 65 Nm (48 ftlb.)
M8
- Tightening torque: 33 Nm (24 ftlb.)
Engine with unit lifting platform
6.3. Lower and remove transmission jack.
6.4. Lower the unit lifting platform -1-, reset it to zero position and remove it.
6.5. Retainer plate 9769 (-1-) must be removed from the unit lifting platform.
Engine mounting
7. Fit anti-roll bar on rear-axle carrier side section.
Move anti-roll bar -2- into position and screw in and tighten M8 x 40 screws -1-.
- Tightening torque: 23 Nm (117 ftlb.)
Anti-roll bar
8. Fit drive shafts on the transmission side.
8.1. Counter using special tool adapter plate 9510/1 (-1-).
Retaining tool for drive-shaft bolts
8.2. Screw in and tighten the six M10 bolts between the drive shaft and transmission flange.
Drive shaft
- Tightening torque: 81 Nm (60 ftlb.)
9. Install the transverse strut.
Fit cross member -2- and screw in and tighten M10 x 72 screws -1-.
- Tightening torque: 65 Nm (48 ftlb.)
Transverse strut
10. Install support plate.
Support plate
10.1. Install support plate.
Fit support plate -2- and screw in and tighten M10 x 25 screws and M10 nuts.
- Tightening torque: 65 Nm (48 ftlb.)
- Tightening torque: 65 Nm (48 ftlb.)
10.2. Install diagonal braces.
Fit diagonal braces -1- and screw in and tighten M10/M12 screws and M10 nuts.
M10
- Tightening torque: 65 Nm (48 ftlb.)
M12
- Tightening torque: 110 Nm (81.5 ftlb.)
Subsequent work
1. Checking and topping up oil for final drive
2. Check ATF level and top up if necessary.
3. Install left rear wheel.