CV Joints – Installation – 2.5L NA

Overview

This guide outlines the procedure to install the Constant Velocity (CV) Joints on the rear axles of all Porsche 944 variants with an 8-valve engine, covering model years 1983–1985.5 (Pre-85.5) and 1986–1988 (85.5 Onwards). Proper installation ensures the CV Joints function smoothly, preventing noise or vibration and extending the life of the drivetrain components. This procedure assumes the CV Joints have been cleaned, inspected, or replaced, and follows the removal process.

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Tools Required

• 8mm (5/16 inch) 12-point internal tool (cheesehead or triple square tool)
• Metric socket set
• Channel lock pliers
• External snap ring pliers
• Hammer
• Deep socket (suitable for tapping concave washer)
• Torque wrench
• Rags

Parts Required

• CV Joint grease (Moly-based)
• Replacement cheesehead bolts (if original bolts are damaged, part number not specified)
• CV Joint Kit (944 331 901 00, if replacing damaged CV Joint)
• Boot Kit (944 331 903 00, if replacing damaged boot)

Step-by-Step Procedure

Step 1: Prepare CV Joint Components

1. Clean all CV Joint parts (inner race, outer race, ball bearings, and splines) with solvent and rags, ensuring no debris remains.
2. Inspect the CV Joint components for wear or cracking. If damaged, replace with a new CV Joint Kit (944 331 901 00).

Step 2: Assemble CV Joint

3. Apply a small amount of Moly-based CV Joint grease to the ball bearing grooves on the inner race.
4. Press the ball bearings into the inner race using your fingers until they snap into place.

5. Align the ball bearings with the grooves in the outer race and tilt the inner race to insert it into the outer race. Tech Tip: If insertion is difficult, remove the ball bearings, insert the inner race into the outer race, then tilt the inner race to insert the ball bearings one at a time.

Step 3: Install CV Joint Boot

6. Inspect the CV Joint boot (944 331 903 00) for rips, tears, or wear. Replace if necessary.
7. Apply a small amount of grease or silicone spray to the axle shaft opening in the boot to ease installation.

8. Slide the boot onto the axle shaft, ensuring it sits properly without twisting.

Step 4: Install Concave Washer

9. Slide the concave washer onto the splines of the axle shaft.
10. Use a hammer and a deep socket to gently tap the washer down until it reaches the bottom of the splines.

Step 5: Repack CV Joint with Grease

11. Thoroughly pack the assembled CV Joint with Moly-based CV Joint grease, ensuring all moving parts are well-lubricated.

12. Apply a small amount of grease to the axle splines to facilitate CV Joint installation.

Step 6: Install CV Joint onto Axle

13. Check the alignment marks made during removal on the axle shaft and CV Joint components (inner and outer races).

14. Slide the CV Joint onto the axle shaft, ensuring all marks are aligned for proper orientation.
15. Install the circlip on the end of the axle shaft using external snap ring pliers to lock the CV Joint in place.

Step 7: Secure CV Joint Boot

16. Tap the CV Joint boot collar into place on the CV Joint housing using a hammer, ensuring a secure fit.

Step 8: Reinstall Drive Axle

17. Position the drive axle back into the vehicle, aligning it with the transaxle and wheel hub.
18. Install the cheesehead bolts at both ends of the axle (transaxle and wheel hub) finger-tight first. (Pre-85.5): Applies to axles 477 501 103 (manual) or 477 501 101A/477 501 102A (automatic). (85.5 Onwards): Applies to axles 944 332 038 01 (manual) or 944 332 038 02/944 332 038 03 (automatic).
19. If any cheesehead bolts were damaged during removal, replace them with new bolts.

Step 9: Torque CV Joint Bolts

20. Use the 8mm (5/16 inch) 12-point internal tool and a torque wrench to tighten the cheesehead bolts to 42 Nm (30 ft-lbs).
21. Lock the rear wheel to prevent rotation while torquing. Options include:

– Place a block under the wheel if the car is low enough.

– Have an assistant hold the wheel.

– Engage the parking brake or place the transaxle in gear.

Step 10: Lower Vehicle

22. Carefully remove the vehicle from the jack stands and lower it to the ground.

Post Procedure Checklist

• Verify that all cheesehead bolts are torqued to 42 Nm (30 ft-lbs) and secure.
• Check that the CV Joint boot (944 331 903 00) is properly seated and free of twists or damage.
• Ensure the drive axle is correctly aligned with the transaxle and wheel hub, with no play or misalignment.
• Confirm all tools and parts are accounted for and stored properly.
• Test drive the vehicle slowly, gradually increasing speed, and listen for any unusual noises or vibrations from the rear axles.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• YouTube