122-A6R3Q-05

911 (996)
Technical Information
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ENU
3902
3
Cardan Shaft (Hardy disc)
Vehicle Type:
911 Carrera 4 (996)/911 Carrera 4S (996)
911 Turbo (996)/911 Turbo S (996)
Model Year:
As of 1999 up to 2005
Concern:
Replacing Hardy disc on the cardan shaft during repairs
Notes:
Previously, the Hardy disc ( Figure 1) was not available separately, and the entire cardan shaft had to
be replaced. In order to improve the serviceability of these vehicles, we have now made the Hardy disc
available as a separate part and it can be replaced independently of the cardan shaft, if required.
Figure 1
PCG.421.020.01
1x
 Hardy disc
996.421.145.01
1x
 Boot
Materials:
000.043.305.73
1x
Olista Longtime 3 EP (80g)
Tools:
V.A.G 1383 A - Transmission jack
Parts Info:
9255 - Assembly sleeve
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911 (996)
3902
ENU
Technical Information
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DANGER
Vehicle can fall down
•
Risk of squashing or crushing
•
Risk of damage to the vehicle

Do not place any solid objects under the raised vehicle.

Ensure that the lifting platform is prevented from lowering.

Remove solid objects before lowering the vehicle.

Raise the vehicle only at the jacking points provided.

The outer jacking points should be used primarily.
Work Procedure: 1
Preparatory work
1.1
Raise the vehicle at the prescribed jacking points (  Workshop Manual '400 Lifting the
vehicle').
1.2
Remove underbody covers (rear and
center  Figure 2 ) (  Workshop Manual
'519019 Removing and installing cover for
underbody').
1
2
3
– Underbody cover – center
– Underbody cover – rear
– Underbody cover – side
Information
•
•
1.3
Observe maximum joint angle of 20°
during removal and fitting.
Figure 2
The cardan joint must not be loaded at maximum deflection (lock).
Remove cardan shaft (  Workshop Manual '390219 Removing and installing cardan shaft').
1.3.1
ONLY for vehicles with manual transmission:
Support manual transmission in installation position with transmission jack.
Remove transmission bracket/transmission support (4 x hexagon nuts).
Secure transmission on the gear support with screws (2 x).
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2017© Porsche Cars North America, Inc.
911 (996)
Technical Information
1.3.2
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ENU
3902
3
Remove hexagon-head bolt, M10 x
35 (3 x) on cardan shaft ( Figure 3
).
1
2
3
– Hexagon-head bolt, M10 x
35
– Cardan shaft
– Hardy disc
1.3.3
Press cardan shaft off the transmission flange using two mounting
levers.
1.3.4
Pull cardan shaft out of the toothed
bush profile of the central shaft and remove it.
1.3.5
Pull bellows off the central shaft
( Figure 4 ).
1
2
3
Figure 3
– Bellows
– Shaft inlet on front-axle
final drive
– Front-axle final drive
bracket – rear
Figure 4
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AfterSales
Apr 25, 2017
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911 (996)
3902
ENU
2
Replace Hardy disc
1
2
3
4
3
Technical Information
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–
–
–
–
Cheese head bolt, M10 x 35
Hardy disc
Cardan shaft flange
Cardan shaft bush
2.1
Remove cheese head bolt, M10 x 35 (3 x)
( Figure 5 ).
2.2
Remove Hardy disc and clean cardan shaft
flange.
2.3
Fit new Hardy disc using the old cheese head
bolts, M10 x 35 (3 x).
Tightening torque 45 Nm (33 ftlb.)
Concluding work
Figure 5
3.1
Installing cardan shaft
1
2
3
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– Assembly sleeve 9255
– Splined shaft profile on cardan shaft
– Boot (bellows)
3.1.1
9255 - Assembly sleeve must
be pushed over the splined shaft
profile of the cardan shaft ( Figure
6 ). Then apply a light coating of
Vaseline.
3.1.2
Push new boot (bellows) as far as it
will go onto the sleeve.
3.1.3
Grease bush on cardan shaft flange ( Figure 5 -4-) with approx. 3g of Olysta
Longtime 3 EP.
3.1.4
Pull assembly sleeve off the cardan shaft splines and grease splined shaft profile
with Olysta Longtime 3 EP.
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Figure 6
2017© Porsche Cars North America, Inc.
911 (996)
Technical Information
3.1.5
1/17
3902
3
Push splined shaft of cardan shaft
into the central bush/shaft on the
transmission and loosely pre-fit
the other end of the cardan shaft
(flange with Hardy disc).
1
2
3
4
3.1.6
ENU
– Boot (bellows)
– Cardan shaft
– Central bush/shaft on
transmission
– Groove on central
bush/shaft
Figure 7
Push collar of boot (bellows) as far
as required into the central shaft on the transmission until the seam engages in the
groove on the central shaft.
Check that the boot (bellows) is fitted perfectly by pulling it at the folds.
3.2
Screw cheese head bolt securing Hardy disc to transmission flange on securely.
Tightening torque 45 Nm (33 ftlb.)
3.3
ONLY for vehicles with manual transmission:
3.3.1
Remove screw (2 x) on gear support.
3.3.2
Secure transmission bracket/transmission support (1 x hexagon-head bolt, M10 x
90) to transmission mount.
Tightening torque 65 Nm (48 ftlb.)
3.3.3
Secure transmission bracket/transmission support (41 x hexagon-head bolt, M10
x 48) to the body.
Tightening torque 65 Nm (48 ftlb.)
39 02 31 40:
Dealership
Distribution
Routing
3.4
Install underbody covers (rear and center  Figure 2 ) (  Workshop Manual '519019
Removing and installing cover for underbody').
3.5
Lower the vehicle and remove it from the lifting platform.
–Converting cardan shaft (1 x)–
Includes:
Removing and installing underbody panelling and cardan shaft.
Converting Hardy disc.
Labor time: 130 TU
Service Manager
_______
Shop Foreman
_______
Service Technician
________
_______
_______
_______
Asst. Manager
_______
Warranty Admin.
_______
Service Technician
________
_______
_______
_______
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