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Drive shaft "cup" replacement


Shaun_E

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  • Support Team

When Andy at PGM was corner weighting my car, he noticed some grease on the side of the diff which looked like it was coming from the drive shaft "cup". I removed the drive shaft on Saturday and it was obvious where the grease was coming from:

IMG_1274.thumb.JPG.df9b85af228b3fd3c14028006ffe8378.JPG IMG_1273.thumb.JPG.d3be4e9a0496babdb97182ca60597b8b.JPG

So a few questions:

  1. Is it easy enough to replace the "cup"? 
  2. Does anyone have the part number and a good source?
  3. Any thoughts on how this occurred and how to prevent it happening again? It looks like it's been rubbing on the diff housing and has worn through.

Thanks, 

Shaun

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  • Support Team

Thanks Guy. Does that have the metal cup/can as well as the gaiter/bellows? I can't find anywhere on line that has stock of that part number so wouldn't want to leave you without your spare.

I found part number 6127557 which appears to include the cup/can but has slightly different dimensions for the gaiter (1mm longer and, probably more importantly, 1mm smaller diameter around the driveshaft (21mm vs 22mm). I'm sure it could be made to fit but I'm concerned that it would eventually fail again.

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Shaun,

the larger end of the boot actually fits on a rolled edge of the can so if brought as a kit shouldnt matter.

I have a spare one - I bought 4 kits when they were available but you only need to cut off one can per drive shaft to change both boots. 1 peening activity didn’t go well hence I only have one spare! I have a spare O ring if you want me to measure it.

Ian

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Bingo - Autodoc in Germany seem to have stock. I've used them for Porsche parts and they take about a week to arrive. For suspension top mounts for the 996 I paid a quarter of the OEM price for parts with the Porsche ref number ground off!

https://www.autodoc.co.uk/spidan/7118105

Do your due diligence to ensure they are the right ones & everything in the picture is included.

 

Ian

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  • Support Team

So my repair kit arrived and it looks very much like the one in Guy's picture. The dimensions of the "can" seem right - diameter and length identical. The rubber bellows measure up to the advertised dimensions but there is one issue - the driveshaft is 32mm in diameter and the smaller end of the bellows is 22mm - is this correct? I hadn't even thought to measure the driveshaft! Looks like the bellows will stretch enough to fit but I'd like to know this is normal.

I guess replacement steps are:

  1. Remove the metal tie wraps
  2. Remove old bellows
  3. at this point it looks like the drive shaft will separate at the point hidden by the bellows
  4. lever away/remove the "lip" on the old can at the larger end
  5. slide old can off
  6. slide new can on
  7. "peen" the can to form a new lip 
  8. slide new bellows onto driveshaft
  9. rejoin driveshaft
  10. Fit new tie wraps

I can see there are new O rings in the kit and I guess it's reasonably obvious where these go and at what point to fit them but any tips gratefully received. At which stage should the new grease be added?

Finally, what is the best way to peen the new lip on the can?

Thanks, Shaun

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Good morning Shaun, I have just measured my bellows and it's 22mm on the shaft end so I guess that's correct as I have fitted one without any problems.

The peening is just a matter of lots of tapping round and round with a small hammer, two things to be careful off.

1. Keep the joint fully compressed ALL OF TIME whilst peening, this is difficult, I held it in a large vice.

2. Protect the shaft from wayward hammer blows which will cause damage, I held a small piece of 3/5mm steel against the shaft as protection.

I hope this all makes sense, i am not known for my grammar *whistle*

Guy

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  • 4 years later...

I referenced the Haynes Sierra manual, bit basic but if you message me your email I could scan the relevant pages. 
 

Word of warning, it's not that easy as stated above. Best to use a puller to pull on and swage the new cans and you have to be very accurate when you swage. Just saying *whistle*77B370D9-90DD-44D1-A4DD-8A1895293444.thumb.jpeg.85494546e353b1cf25873cd88fcf7994.jpegD09C9A67-061F-4980-A525-8D28F860778B.thumb.jpeg.ccfac7f0d7c8235ea5b1d5490813c994.jpeg

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