Intermediate Shaft

Intermediate Shaft

Removal





1. NOTE: Use an Allen key to stop the piston rod from turning.

Undo the right-hand suspension strut top nut by five turns.
2. Raise the vehicle.





3. Detach the right-hand suspension arm.

CAUTION: The inner joint must not be bent at more than 18 degrees.





4. NOTE: Do not damage the gaiter.

Detach the right-hand front drive halfshaft from the intermediate shaft.
- Separate the clamping strap and slide back the gaiter.
- Pull out the front drive halfshaft from the tripod housing.
- Remove the grease.
- Secure the front drive halfshaft.





5. NOTE: Escaping oil.

Remove the intermediate shaft.
- Remove the retaining clip.
- Pull the intermediate shaft from the transmission.
- Close off the transmission with auxiliary plugs.

Installation

All vehicles





1. CAUTION: Do not damage the oil seal when inserting the front drive halfshaft. In the case of the iB5 transmission, use an installation sleeve (supplied with each new oil seal).

Install the intermediate shaft in the transmission.





2. NOTE: Renew the retaining clip and nuts on the intermediate bearing.

NOTE: Insert the intermediate shaft into the transmission until the intermediate shaft bearing touches the rib of the intermediate shaft bracket.

Install the intermediate shaft in the transmission.
- Install the retaining clip.

CAUTION: The inner joint must not be bent at more than 18 degrees.





3. Install front drive halfshaft.
- Pack the tripod joint with grease for the inner joint.
1 Insert a small screwdriver under the gaiter seat to allow the air to escape.
2 Slide the tripod joint in as far as the stop, then pull it out 20 mm.
- Remove the screwdriver.





4. Insert the clamping strap in the gaiter ring groove and tighten it with the locking clamp.
- Insert the clamping strap in the gaiter ring groove.





5. Attach the right-hand suspension arm.

Vehicles with iB5 manual transmission
6. Check the transmission fluid level.

Vehicles with MTX75 manual transmission
7. Check the transmission fluid level.

All vehicles
8. Lower the vehicle.





9. Tighten the right-hand suspension strut nut.
- Stop it from turning using an Allen key.
- Tighten by hand with a ring spanner.
- Use a torque wrench to tighten to torque.