Drive/Propeller Shaft: Service and Repair Removing and Installing Rear Cardan Shaft Removing and installing rear cardan shaft Tools

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Vincent Marshall
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1 2005 Porsche Cayenne V8-4.5L Page 1 Drive/Propeller Shaft: Service and Repair 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. emoving 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. ear cardan shaft to transfer box

2 2005 Porsche Cayenne V8-4.5L Page 2 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 2005 Porsche Cayenne V8-4.5L Page 3 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. ardan 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

4 2005 Porsche Cayenne V8-4.5L Page 4 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. ardan 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

5 2005 Porsche Cayenne V8-4.5L Page 5 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-. ardan shaft centre bearing to body 8. Carefully separate cardan shaft from transfer box ->Removing cardan shaft and press backwards. emoving 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. emoving 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

6 2005 Porsche Cayenne V8-4.5L Page 6 3. Mark the position of the cardan shaft -arrow- with respect to the transfer box flange with a colored pen. Mark for ear cardan shaft to transfer box 4. Loosen fastening screws -arrows- securing cardan shaft support to centre bearing. ardan shaft support to centre bearing

7 2005 Porsche Cayenne V8-4.5L Page 7 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. ear cardan shaft to transfer box 5. Unscrew fastening screws on the cardan shaft at the rear axle transmission. ->Cardan shaft to rear final drive. ardan shaft to rear final drive

8 2005 Porsche Cayenne V8-4.5L Page 8 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-. amper to transfer box 7. Unscrew fastening screws -arrows- on the cardan shaft at the transfer box. Counter with an open-ended wrench. ardan shaft to transfer box 8. Release cardan shaft centre bearing holder. To do this, unscrew six fastening screws -arrows-. ardan shaft centre bearing to body

9 2005 Porsche Cayenne V8-4.5L Page 9 9. Carefully separate cardan shaft from transfer box and press backwards -arrow-. emoving 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. nstalling 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.

10 2005 Porsche Cayenne V8-4.5L Page 10 ^ 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. ardan shaft centre bearing to body 4. Position the cardan shaft at the color markings -arrow-again. arking on transfer box flange/cardan shaft

11 2005 Porsche Cayenne V8-4.5L Page 11 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. atch 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 ardan shaft to rear final drive

12 2005 Porsche Cayenne V8-4.5L Page Tighten bolts connecting cardan shaft triangular flange to transfer box -arrows-. Counter with an open-ended wrench. Tightening torque 56 ft. lbs. ardan shaft to transfer box 7. Screw in fastening screws for securing cardan shaft centre bearing holder to body -arrows-. Tightening torque 44 ft. lbs. ardan shaft centre bearing to body Note:

13 2005 Porsche Cayenne V8-4.5L Page 13 ^ Centre bearing must be installed without tension. ^ Fit special tool centering tool >Special tool in installation position in the specified sequence. pecial tool in installation position 8. Mount special tool centering tool 9680-arrow,inset-. ounting special tool Press on special tool centering tool 9680 in sequence according to numbering -1, 2-. ressing on special tool Tighten bolts -arrow- connecting holder to centre bearing. Tightening torque 15 ft. lbs.

14 2005 Porsche Cayenne V8-4.5L Page 14 Cardan shaft support to centre bearing 11. Remove special tool centering tool arrowsemoving special tool 9680 nstalling rear 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. atch 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.

15 2005 Porsche Cayenne V8-4.5L Page 15 Note: ^ Centre bearing must be installed without tension. ^ Fit special tool centering tool >Special tool in installation position in the specified sequence. pecial 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.

16 2005 Porsche Cayenne V8-4.5L Page 16 Cardan shaft centre bearing to body 4. Position the cardan shaft at the color markings -arrows-again. arking 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 ardan shaft to rear final drive

17 2005 Porsche Cayenne V8-4.5L Page Secure damper on transfer box. To do this, screw in six fastening screws -arrows-. Tightening torque 24 ft. lbs. amper 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. ardan shaft to transfer box 8. Screw in fastening screws -arrows- for securing cardan shaft centre bearing holder to body. Tightening torque 44 ft. lbs. ardan shaft centre bearing to body

18 2005 Porsche Cayenne V8-4.5L Page Mount special tool centering tool ounting special tool Press on special tool centering tool 9680 in sequence according to numbering -1,2-. ressing on special tool Tighten bolts -arrows- securing holder to centre bearing. Tightening torque 15 ft. lbs. ardan shaft support to centre bearing

19 2005 Porsche Cayenne V8-4.5L Page Remove special tool centering tool arrowsemoving special tool 9680 ubsequent work - rear cardan shaft 1. Install the exhaust system.

REMOVING CYLINDER HEAD COVER (VALVE COVER) - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) > PRELIMINARY WORK > PRELIMINARY WORK

Page 1 of 9 CYLINDER HEAD, VALVE DRIVE 15 82 21 REMOVING CYLINDER HEAD COVER (VALVE COVER) - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) > PRELIMINARY WORK > PRELIMINARY WORK 1. Remove engine compartment