Parts Catalog Accessories Catalog Tech Info Tech Forums
 
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
Click here to view Part Diagrams
Get FREE Ground Shipping with the purchase of $75 in qualifying parts!
 

Bookmark and Share

 


Pelican Technical Article:
Driveshaft Bearing Support and Flex Disc Replacement

Jared Fenton

 
Time: 1 hour
Tab: $430-540
Talent:  
Tools:
13mm, 15mm socket, 5mm hex driver, 18mm wrenches, razor blades, Air grinder, Sawzall or hacksaw.
Applicable Models:
Cayenne (2003-08)
Cayenne S (2003-08)
Cayenne Turbo (2003-08)
Parts Required:
EPS Driveshaft Support
Hot Tip:
Wear safety glasses when cutting old support
Performance Gain:
Smoother driveline
Complementary Modification:
Change transmission fluid
 
   

   
Check out some other sample projects from the book: 
Need to buy parts for this project?
Click here to order parts for your Porsche from our parts catalog
   
     The driveshaft center bearing support is used to dampen vibration and lateral movement of the driveshaft as it spins. The factory design of the rubber seems to be a bit weak for the job, usually resulting in the rubber cracking or tearing due to age and the elements. When the rubber starts to fail, you'll notice an odd vibration coming from the center console when accelerating. This vibration will only get worse over time, eventually turning into a loud knocking noise.

     The factory fix for the support is to remove the driveshaft from the car, disassemble it and use a new center support (with the same rubber centered design) when reassembling it. EPS has devised a solution that does not require driveshaft removal, and does a better job of supporting the driveshaft.

     The EPS solution re-uses the bearing already on the driveshaft. You'll want to check that the bearing is still in good shape once you cut away the rubber. It should spin freely, with no binding or noise. If the bearing does any of these things, its finished and you'll have to install a rebuilt driveshaft or remove the existing driveshaft and have a new bearing installed. Hence, why you should inspect the support if you start feeling an odd vibration.

     In this article, we will go over the steps involved with removing the old support and installing the EPS support. Additionally, we will go over the steps with replacing the front flex disc on the driveshaft.

     The flex disc is a rubber reinforced coupler that isolates vibration from the rest of the drivetrain, while transferring power from the engine and transmission to the rear differential and wheels. When the center support begins to fail, it can put increased stress on the flex disc, causing it to crack. Over time, the cracks grow due to centrifugal force and can eventually fly apart in chunks if they are seriously neglected. The EPS package includes a new flex disc if yours is worn.

     Begin by jacking up your Cayenne and placing it on four jack stands rated for at least 6000 lbs. (See our article on Jacking Up Your Cayenne for more information). You'll need to jack the car high enough to access the center underside.
Begin by removing the six 15mm bolts (green arrows) holding the support plate to the chassis.
Figure 1
Begin by removing the six 15mm bolts (green arrows) holding the support plate to the chassis. Then remove the two 13mm bolts (yellow arrows) holding the driveshaft bearing support to the support plate.
Large Image | Extra-Large Image
Shown here is the driveshaft bearing support.
Figure 2
Shown here is the driveshaft bearing support. You can see the tear in the rubber mount (green arrow). You'll want to cut through the remaining rubber so that you can slide the outer metal sleeve towards the front of the car.
Large Image | Extra-Large Image
Slide the outer sleeve towards the front of the car.
Figure 3
Slide the outer sleeve towards the front of the car. You'll need the access in order to cut through the sleeve.
Large Image | Extra-Large Image
The outer sleeve must be cut through in order to remove it from the driveshaft.
Figure 4
The outer sleeve must be cut through in order to remove it from the driveshaft. An air grinder as shown here makes short work of this job. You can also use a Sawzall or even a hacksaw if needed. The idea here is to make one cut through and then bend the sleeve to clear the driveshaft.
Large Image | Extra-Large Image
Shown here is an example of the cut you need to make (green arrow).
Figure 5
Shown here is an example of the cut you need to make (green arrow). Once cut, bend the sleeve to clear the driveshaft.
Large Image | Extra-Large Image
Use a razor blade to cut away the remaining rubber on the bearing.
Figure 6
Use a razor blade to cut away the remaining rubber on the bearing. At this point, check that the bearing spins freely and doesn't bind or make noise. If the bearing shows signs of failure, you'll need to stop now and remove the entire driveshaft.
Large Image | Extra-Large Image
Shown here is the bearing after a good amount of the rubber has been cut away (green arrow).
Figure 7
Shown here is the bearing after a good amount of the rubber has been cut away (green arrow). The idea here is to remove as much rubber as you can until the outer bearing surface is smooth. A few patches of rubber aren't going to hurt anything.
Large Image | Extra-Large Image
Here is the improved center support sleeve as designed by EPS.
Figure 8
Here is the improved center support sleeve as designed by EPS. As you can see, the bearing is manufactured in two pieces, allowing you to clamp it over the existing bearing on the driveshaft. The inner sleeve is supported by polyurethane bushings instead of the solid rubber design.
Large Image | Extra-Large Image
Slide the upper part of the EPS support up and over the center bearing (green arrow).
Figure 9
Slide the upper part of the EPS support up and over the center bearing (green arrow). Note the orientation of the support. It has to go on in the direction shown here.
Large Image | Extra-Large Image
Attaching the lower part of the EPS mount uses two mounting holes and two channels on either side.
Figure 10
Attaching the lower part of the EPS mount uses two mounting holes and two channels on either side. Use a long shaft 5mm driver as shown here to route the screws up through the plate (green arrow) for the inner sleeve and the channels on the side (yellow arrow) for the outer sleeve. The longer supplied screws fit into the inner sleeve, while the shorter screws fit into the outer sleeve. Once the lower part of the mount has been attached, tighten the 5mm bolts.
Large Image | Extra-Large Image
When re-installing the support plate, thread the outer, 15mm bolts in first (green arrows) and torque them to 60NM (44 ft/lbs).
Figure 11
When re-installing the support plate, thread the outer, 15mm bolts in first (green arrows) and torque them to 60NM (44 ft/lbs). Then install the two 13mm bolts holding the EPS support to the support plate. You may have to move the mount around slightly for the holes to line up. Torque the 13mm bolts to 20Nm (15 ft/lbs).
Large Image | Extra-Large Image
Shown here is the new flex disc supplied in the kit from EPS.
Figure 12
Shown here is the new flex disc supplied in the kit from EPS.
Large Image | Extra-Large Image
The flex disc is bolted to both the driveshaft and also the output shaft of the transmission.
Figure 13
The flex disc is bolted to both the driveshaft and also the output shaft of the transmission. You'll want to inspect it thoroughly for cracks around the bolts and also the outer edges. If the flex disc shows any signs of wear, replace it.
Large Image | Extra-Large Image
Loosen and remove the six 18mm nuts and bolts holding the flex disc between the output shaft and the driveshaft.
Figure 14
Loosen and remove the six 18mm nuts and bolts holding the flex disc between the output shaft and the driveshaft. These will take a bit of muscle to break free. If you don't have an impact wrench, I recommend putting the parking brake on and even having a helper press the brakes when attempting to loosen the bolts. Then you can also have the helper let off the brakes so you can rotate the drive shaft for better access to the bolts. Once the new flex disc is installed, Torque each nut and bolt to 30Nm (22 ft/lbs.) and then turn each bolt an additional 90 degrees.
Large Image | Extra-Large Image
Need to buy parts for this project?
Click here to order parts for your Porsche from our parts catalog
Bookmark and Share
Comments and Suggestions:
jeezcak3 Comments: Dear Admin - The image links are broken. Could you please relink them? Please let me know once complete. Thanks!!!
September 10, 2016
  Followup from the Pelican Staff: Thanks for the catching the site error. We appreciate it. I will have the article updated.
- Nick at Pelican Parts
 
L Comments: on the 06 cayenne s my husband used 11mm, 16mm to take the 6 bolts off, and 13mm to take the other 2 bolts off. just in case anyone needed to know
September 9, 2016
  Followup from the Pelican Staff: Thanks for the additional info and feedback. We appreciate it.
- Nick at Pelican Parts
 
Sting7777 Comments: I found that bolt cutters worked well for removing the old carrier. And a micro butane torch helped soften the rubber when scraping off with a razor blade. A long t-handle 5mm hex wrench also made things go smoother. I repacked the bearing with synthetic bearing grease before mounting the EPS carrier. This mount and procedure works on later models as well. Mine is a 2009.
May 19, 2016
  Followup from the Pelican Staff: Thanks for the additional info. We appreciate it.
- Nick at Pelican Parts
 
IrfanBK Comments: Hi, It's a pleasure to read and look at the pictures of the repairs. A picture speaks a thousand words. Thanks and keep up the great work.
February 5, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
C.k.cheong Comments: Porsche cayenne drive shaft center clamping EPS how much the price…
Because i at Malaysia ~
November 1, 2015
  Followup from the Pelican Staff: We may not ship there. To be sure, Give our parts specialists a call at 1-310-626-8765 - Nick at Pelican Parts  

Check out some other sample projects from the book: 
 

Got more questions?  Join us in our Technical Discussion Forums

Or, see what other questions readers have asked about this article...
  Applies to: Cayenne (2003-08), Cayenne S (2003-08), Cayenne Turbo (2003-08)
  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Project/Wish List]
  [Privacy Statement]  [Contact Us] [About Us] [Shipping] [Careers]

Copyright © Pelican Parts Inc. -    DMCA Registered Agent Contact Page