SEAT Workshop Service and Repair Manuals

Driveshaft from year 2001 models onwards: repairing

Special tools and workshop equipment required

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Terminal crimper -VW 407-

t	Terminal crimper -VW 408 A-

t	Support sleeves -VW 522-

t	Tensor -40-204 A-

t	Pliers -V.A.G 1275-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Pliers -V.A.G 1682-

Filling the exterior constant velocity joint with grease: Total amount of grease: 180 g of lubricating grease -G 000 603- t  Insert approx. 90 g of grease into the outer joint through the inner gears of the ball hub. t  Spread approx. 90 g on the inside of the seal. t  If the dust guard is replaced, the seal may need to be re-greased. Filling the inner constant velocity joint with grease: Total amount of grease: 120 g of lubricating grease -G 000 603- t  Apply approx. 60 g of grease on both sides of the seal. t  If the dust guard is replaced, the seal may need to be re-greased.

1 -	Tightening clip

q

Replace

q	Tighten → Fig.

2 -	Constant velocity exterior joint

q	Only replace entirely

q	Releasing → Fig.

q	Checking → Chapter

q	insert into the driveshaft using a plastic hammer, until the compressed circlip is decompressed

q

Grease →

3 -	Hexagonal bolt

q	150 Nm, and turn a further 90°

q	When tightening and loosening, the vehicle must rest on its wheels

q	Replace after each removal

4 -	Driveshaft

5 -

Circlip

q

Replace

q	Insert in the driveshaft groove

6 -	Tightening clip

q

Replace

q	Tighten → Fig.

7 -	Dust guard for constant velocity joint

q	Material: Hytrel (polyester elastomer)

q	Without ventilation opening

q	Check for cracks or wear, and replace if necessary

8 -

Circlip

q

Replace

9 -	Inner constant velocity joint

q	Only replace entirely

q	Releasing → Fig.

q	Checking → Chapter

q	Fitting → Fig.

q	The bonding surfaces must be free of grease and oil

q

Grease →

q	Insert and remove with long nose pliers

10 -

Cover

q	Carefully remove using an awl

q	Apply D-3 on the seal surface before connecting it to the constant velocity joint

q	The bonding surface must be free of grease and oil!

11 -	Tightening clip

q

Replace

q	Tighten → Fig.

12 -	Dust guard of the inner constant velocity joint

q	With breather hole

q	Check for cracks or wear, and replace if necessary

q	Clean the driveshaft properly before fitting the new dust guard

q	Before fitting the dust guard, grease the driveshaft profile slightly

13 -	Additional plate

14 -	Bolt with internal splined head

q	First tighten diagonally to 10 Nm

q	Tighten completely to 70 Nm

q	Replace after each removal

15 -

Cover

q	Carefully remove using an awl → Fig.

q	The bonding surface must be free of grease and oil!

q	Apply D-3 on the seal surface before connecting it to the constant velocity joint

16 -

Seal

q	Replace, remove the protection layer and attach it to the joint.

Removing the exterior constant velocity joint –  Secure the driveshaft in workshop vice with the claws. –  Push the dust guard backwards. –  Remove the constant velocity joint from the driveshaft using an awl -A-. The awl must be positioned exactly onto the star of the seal. Position the seal –  Insert into the driveshaft using a plastic hammer, until the safety ring fits into position.

Tightening of the large clamp of the outer constant velocity joint –  Position the pliers V.A.G 1682, as shown in the figure. Ensure that the edges of the tool fit into the corners -arrows B- of the clamp. –  Tense the clip by turning the screw using the torque wrench taking special care not to incline the pliers during the operation.   Note t  Given the firmness of the material (in comparison with the rubber) of the union dust guard, a stainless steel clamp is required, this can only be tightened using the pliers -V.A.G 1682-. t  Tightening torque: 25 Nm t  Use a torque wrench-C- with a range between 5 and 50 Nm (e.g. -V.A.G 1331-). t  Check that the spindle thread -A- of the pliers can be tightened without forcing. Apply grease -MOS 2-, if necessary. t  If the thread does not turn easily (due to dirt, for example), it will not be possible to tighten the clamp sufficiently when applying the specified torque.

Tighten the small clamp of the outer joint

Tightening of the large clamp of the inner joint

Separate the cover from the inner CV joint

Removing the interior constant velocity joint –  To do so, press on the ball hub. –  The securing ring must first be removed with pliers. –  Release the clamp and move the dust guard backwards. –  Remove the cover with an awl. –  Remove the constant velocity joint. –  Hold the driveshaft down.

Fit the inner constant velocity joint –  Tighten carefully using the tensor -40 - 204 A-, taking care not to damage the corrosion protection of the driveshaft.   Note The bevel of the interior diameter of the ball hub (cogged) must face the support collar of the driveshaft. –  Insert the constant velocity joint up to the limit. –  Insert the securing ring.