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Intermediate shaft, V6

Intermediate shaft, V6

To remove


1. Lift off the battery cover.


2. Remove the negative lead from the battery.

3. Lay down wing protectors and remove the generator cooling bellows (snap fastening).

4. Relieve the belt tensioner with a 15 mm socket wrench in the centre and lift off the multigroove belt.


5. Remove the belt tensioner.

6. Undo the upper generator bolt.

7. Raise the car.

8. Remove the RH wheel.

9. Remove the cover for the belt system.


10. Tap out the drive shaft from the intermediate shaft using a brass drift/hammer.


11. Undo the clips on the brake hose and the ABS cable mountings.

12. Remove the outer suspension arm through bolt from the steering swivel member.

13. Prise loose and lower the suspension arm and secure it in this position with a block of wood between the suspension arm and the anti-roll bar.

14. Turn the wheel to the left for better access to the drive shaft. Knock the drive shaft further out if necessary. Grip the MacPherson strut and pull. The drive shaft will then come with it. Then let it tilt down in front of the suspension arm.

15. Remove the lower generator bolt.


16. Remove the bolts securing the intermediate shaft bearing bracket.

17. Unplug the electrical connection from the oil pressure switch.

18. Tilt up the generator and place a wedge underneath to keep it in position.

19. Place a receptacle under the gearbox and carefully pull out the intermediate shaft.


To fit


1. Fit 83 95 162 Protective collar, drive shafts into the sealing ring.


Important

Always change the shaft seal in the gearbox. Lubricate with transmission fluid, see


2. Make sure that the intermediate shaft is clean and then align the intermediate shaft in the tool.

Important

Fit the intermediate shaft in the gearbox until about 20 mm remains and extract the tool before the shaft's sealing surface reaches the shaft seal.


3. Push in the rest of the shaft.

4. Fit the bearing bracket bolts.

Tightening torque: 45 Nm (33 lbf ft)

5. Ensure the adjuster sleeve on the generator is protruding about 1 mm to facilitate fitting.


6. Fit the lower generator bolt.

7. Connect the oil pressure switch and fasten the cable clips and cable tie.

8. Lubricate the drive shaft splines with universal paste 87 81 684. See . Tilt out the MacPherson strut and attach the drive shaft to the intermediate shaft until the circlip snaps in place. Make sure the dust cover is fitted to the intermediate shaft.


9. Fit the ball joint to the steering swivel member and tighten.

Tightening torque 60 Nm + 90° (44 lbf ft + 90°)

10. Secure the brake hose to the mounting on the steering swivel member and fit the clips. Fit the ABS cable. (2 mountings)

11. Fit the cover for the belt system.


12. Fit the wheel.

Tightening torque 110 Nm (80 lbf ft)

Important

The wheel must be suspended freely when tightening the wheel bolts


13. Lower the car. Fit the belt tensioner and multigroove belt.


14. Tighten the upper generator bolt.

15. Fit the generator cooling bellows.


16. Connect the battery and fit the battery cover.

17. Fill up with automatic transmission fluid to the correct level.

18. Set the clock and radio code if applicable.