Cardan shaft replacement experience

[tabasco]

I replaced the cardan shaft on my 04 Cayenne S.

The original bearing support was broken. The car has only 28K miles, but I guess the Texas heat did not help.

I bought the reconditioned shaft from Vertex, which includes a free flex disk for $350.

I installed it a couple weeks ago.

I had pretty strong vibrations with the new shaft, especially at low speed between 19~23 mph. At higher speeds they went away, but I was not happy. Those vibrations were really annoying, especially in traffic where you stay in that range for long periods.

Then I remembered than during the installation, putting the bolts through the flex disk was unusually hard, like they were not lined up properly, while removing the bolts from the original disc was easy.

So today I replaced the flex disk with my original one, which still looked really good (again, just 28K miles).

Looking at both flex discs closely, the original Porsche disk is different, especially where the metal meets the rubber. Definitely better quality.

The porsche disc went back in really easy, the bolts lined up properly.

And the vibrations went away. The car is really smooth now. Different car !

:-)

BTW I made an alignment tool from a $3.50 PVC fitting (-edit- 1.5" x 3" coupler) that I bored a little on the lathe and then cut in half. It made the alignment of the bearing easy.

Conclusion : if you order the reconditioned shaft from Vertex, put the flex disc in the trash, and get one from the dealer (unless you can reuse your original one). The alternate brands are not the same in terms of quality !

Edited March 8, 2013 by tabasco

[Andrei Marton]

I had to replace the shaft also. But , at 110.000km. The car had extended warranty and went straight to the dealer and replaced it with no cost.

What is strange, is that the broken shat was fractured at the middle, where it has a welded joint. at low speeds was hitting the body underneath. but at higher speeds, it stopped and everything was fine. I think it was a ballance issue...

[gbratk]

BTW I made an alignment tool from a $3.50 PVC fitting (2" - 4" coupler) that I bored a little on the lathe and then cut in half. It made the alignment of the bearing easy.

Can you post some pictures, and maybe some dimensions.

[hahnmgh63]

Good write up. I know many others have had good luck with the Vertex shaft. Did you let Vertex know about the crappy quality flex disc?

[tabasco]

BTW I made an alignment tool from a $3.50 PVC fitting (2" - 4" coupler) that I bored a little on the lathe and then cut in half. It made the alignment of the bearing easy.

Can you post some pictures, and maybe some dimensions.

Sorry for the delay, I finally took some pics tonight.

I used is a 1.5" x 3" PVC coupler. The one I have is made by Charlotte, I bought it at Lowes.

I put it in the lathe, bored the small end to 50mm so that it would fit on the lathe (slightly under 50 actually so that it would fit snug), and faced the big end (just removed the taper and made it perfectly flat). Then I cut it in half.

To use it, I placed the tool on top of the shaft, used it as a square against the bearing.

Then I installed the support plate under it, making sure the tool was not moving. Once the plate is there you can't see if the bearing is still square with the tool but you can feel it with your fingers.

PVC fitting :

Cut in half :

This is how it fits on the shaft (old shaft ready to be shipped). It fits better on a good bearing.

Good write up. I know many others have had good luck with the Vertex shaft. Did you let Vertex know about the crappy quality flex disc?

No, I've not had a chance yet. I'll do that when I send my shaft back.

[gbratk]

Great idea!

I'll make one, and check my alignment.