404119 Removing and installing front drive shaft
WM 404119 Removing and installing front drive shaft
Tools
Technical values
Preliminary work
1. Loosen axle nut.
1.1. Vehicle standing on the ground, get a second mechanic to block the brake.
1.2. Loosen axle nut.
2. Raise the vehicle. -> 4X00IN Lifting the vehicle Service and Repair
3. Remove the wheel -> 440519 Removing and installing wheel Removal and Replacement.
Tools and materials
Puller set Nr.87-1 Pos.1
Screwdriver 9546
Ball joint puller T10187
Ball joint puller T40010
Spring compressor VW 552
PIWIS Tester II 9818
Protective tube - For protecting the drive shaft (shop-made)
Removing drive shaft
Removing front drive shaft
WARNING
Wheel bearing housing raised incorrectly
- Risk of squashing
- Risk of damage to components
-> Wear personal protective gear.
-> Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
Overview of front drive shaft
1. Unscrew drive shaft nut -1-.
Unscrewing axle nut
2. Detach holder for brake hose, carefully unplug connector for speed sensor and remove the brake pad wear indicator cable out of the guides.
3. Release brake caliper and suspend it at a suitable place in the wheel housing. -> 473919 Removing and installing front brake caliper 473919 Removing and installing front brake calliper -> 473919 Removing and installing front brake caliper (PCCB) 473919 Removing and installing front brake calliper (PCCB).
4. Remove brake disc. -> 465019 Removing and installing front brake disc 465019 Removing and installing front brake disc-> 465019 Removing and installing front PCCB brake disc 465019 Removing and installing front brake disc
5. Fix upper trailing arm using spring tensioner VW 552. This involves pre-tensioning the trailing arm slightly, otherwise the top ball joint may be damaged. This is only necessary if the same control arm is reused.
Inserting upper front-axle spring tensioner
6. Puller set Nr.87-1 Pos.1 must be placed on wheel hub and the spindle must be used to push (press) the drive shaft peg into the wheel hub by a maximum of => Control value: +10 mm. Leave the puller fitted (this makes removal easier).
Pressing in drive shaft
7. Remove air guide for brake disc at the lower control arm and push protection (shop-made) over drive shaft.
8. Detach drive shaft on transmission side.
9. Loosen lower spring strut. Support it slightly with a transmission jack if necessary until the screw can be removed. Use a suitable rubber base to prevent slipping!
10. Press ball joint -1- off the cone.
Pressing tie-rod ball off the cone
10.1. Ball joint puller T10187 -2- must be positioned over the ball joint -1- and fitted on the fastening nut -3-.
10.2. Screw in hexagon on the ball joint puller T10187 until the ball joint -1- is released from the cone.
11. Remove lock nut from the bottom ball joint and press off with the ball joint puller T10187. When doing this, leave the lock nut flush on the ball pin so as not to damage the thread.
12. Important: Always hold the drive shaft! In the event of unfavourable tolerances, it is possible that the drive shaft will slip out. Loosen the ball joint at the upper transverse control arm and press it out carefully using the ball joint puller T40010.
13. Remove lock nut from the bottom ball joint. Carefully remove wheel bearing housing together with the drive shaft.
14. Take the drive shaft out of the wheel hub.
Installing drive shaft
Installing front drive shaft
Information
- All the threaded joints on the axle must be tightened in vehicle position. Vehicle position means: vehicle standing on its wheels, or the wheel suspension is raised using a universal vehicle lift. Dimension -X- , from lower edge of wing to middle of axle corresponds to vehicle position. For details of current height values, see -> 4495TW Adjustment values for suspension alignment 4495TW Adjustment values for suspension alignment. Always observe the following points!
Dimension X - centre of wheel to lower edge of wing (rear axle shown)
Steel springs
- The vehicle position is reached at the front axle by placing the vehicle onto the wheels in a suitable work area (wheel alignment platform, workshop pit).
Air suspension
- The vehicle position is reached at the front axle (with air suspension) by bleeding the respective air spring using the Porsche System Tester and carefully lifting the respective wheel bearing housing. -> 4301IN Bleeding and filling the levelling system 4301IN Bleeding and filling the levelling system
- Use an intermediate layer (hard rubber)! Do not damage the brake cover plate.
Raising wheel carrier (air suspension)
- Screws and nuts are Geomet-coated and must not be greased.
- Grease the toothing of the drive shaft slightly with aluminium paste Optimoly TA.
- Drive shafts must not be left hanging from the joint stop! Tie up.
- Use new screws and lock nuts.
- Use correct tightening torques and torque angles. -> 4X00IN00 Tightening torques for front axle
WARNING
Wheel bearing housing raised incorrectly
- Risk of squashing
- Risk of damage to components
-> Wear personal protective gear.
-> Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
1. Grease toothing with a little Optimoly TA aluminium paste and insert drive shaft. When doing this, press inner joint together tightly.
2. Screw on the drive shaft nut to prevent the shaft from slipping out.
3. Tighten the drive shaft.
3.1. In Step 1, "before installation", fit the drive shaft into the wheel hub with => Tightening torque: +130 Nm (+96 ftlb.). To do this, place the wheel carrier with the drive shaft and tool on the floor (do not damage the brake cover plate) and tighten the drive shaft -direction arrow-. A second mechanic is required!
3.2. The second tightening step is performed with the wheel bearing housing installed! Use the specified tightening torque. -> 4X00IN Tightening torques for front axle 4X00IN Tightening torques for front axle
4. Installation is performed in reverse order. => Tightening torques for front axle
5. Raise the wheel carrier using a suitable jack until the fastening bolts for the lower spring strut can be pushed in easily. Use a suitable -lift with rubber base- to prevent slipping (this makes installation easier!).
Raising wheel carrier (air suspension), shown with brake disc and caliper
6. To counter the ball joints, use screwdriver 9546, if necessary.
Subsequent work
Fit the wheel. -> 440519 Removing and installing wheel - section on "Installing" Removal and Replacement
1. Tighten axle nut (drive shaft mounting on wheel side) (2-step tightening procedure!). Operate the brake while doing this (2 mechanics required). -> 4X00IN Tightening torques for front axle 4X00IN Tightening torques for front axle
Information
Vehicles with steel suspension: Tighten lower threaded joint in installation position.
2. Perform suspension alignment. -> 449503 Suspension alignment, complete 449503 Suspension Alignment, Complete