SEAT Workshop Service and Repair Manuals

Repairing drive shaft from model year 2001

Special tools and workshop equipment required

t	Press plate -VW 401-

t	Press plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 408 A-

t	Support sleeve -VW 522-

t	Tensioner -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-

Packing outer constant velocity joint with grease: Total amount of grease: 180 g lubricating grease -G 000 603- t  Press approx. 90 g grease through the inner splines of the ball hub into the outer joint. t  Spread approx. 90 g grease around inside of joint. t  When renewing the bellows, regrease joint if required. Packing inner constant velocity joint with grease: Total amount of grease: 120 g lubricating grease -G 000 603- t  Press approx. 60 g grease into each side of the joint. t  When renewing the bellows, regrease joint if required.

1 -	Clamp-type clip

q

Renew.

q	Tensioning → Fig..

2 -	Outer constant velocity joint

q	Renew only complete.

q	Driving off → Fig..

q	Checking → Chapter.

q	Installing: drive onto shaft with plastic hammer until compressed circlip seats.

q	Greasing → .

3 -	Hexagon bolt

q	150 Nm and turn 90° further.

q	The vehicle must be standing on the ground when loosening/tightening.

q	Renew each time after removing.

4 -	Drive shaft

5 -

Circlip

q

Renew.

q	Insert in shaft groove.

6 -	Clamp-type clip

q

Renew.

q	Tensioning → Fig..

7 -	Bellows for outer constant velocity joint

q	Material: Hytrel (Polyelastomer).

q	No breather hole.

q	Check for tears and chafing, renew if necessary.

8 -

Circlip

q

Renew.

9 -	Inner constant velocity joint

q	Renew only complete.

q	Pressing off → Fig..

q	Checking → Chapter.

q	Pressing on → Fig..

q	Adhesive surface must be free of oil and grease.

q	Greasing → .

q	Remove and install with long nosed pliers.

10 -

Cap

q	Drive off with a drift.

q	Before fitting on constant velocity joint, coat sealing surface with D-3.

q	Adhesive surface must be free of oil and grease.

11 -	Clamp-type clip

q

Renew.

q	Tensioning → Fig..

12 -	Bellows for inner constant velocity joint

q	With vent hole

q	Check for tears and chafing, renew if necessary.

q	Clean drive shaft thoroughly before installing new drive shaft bellows.

q	Lightly grease the drive shaft before installing the bellows.

13 -	Locking plate

14 -	Multi-point socket head bolt

q	Tighten using diagonal sequence to 10 Nm.

q	Tighten to 70 Nm.

q	Renew each time after removing.

15 -

Cover

q	Drive off with a drift → Fig..

q	Adhesive surface must be free of oil and grease.

q	Before fitting on constant velocity joint, coat sealing surface with D-3.

16 -

Seal

q	Renew. Pull off protective foil and stick onto joint.

Driving off outer constant velocity joint –  Clamp drive shaft in vice using vice clamps. –  Fold back bellows. –  Drive constant velocity joint off drive shaft using drift -A-. The drift should be positioned exactly on the cross of the constant velocity joint. Driving joint on –  Drive onto shaft with plastic hammer until securing ring engages.

Tensioning large hose clamp on outer joint –  Position pliers V.A.G 1682 as shown in diagram. Thereby ensure that the jaws of the pliers seat in the corners -arrows B- of the hose clip. –  Tension hose clamp by turning the spindle with a torque wrench (do not cant pliers).   Note t  Due to the hard material of the protective boot (compared to rubber) and, due to the use of a stainless steel clip, it is only possible to tension the clip using pliers -V.A.G 1682-. t  Specified torque: 25 Nm. t  Use torque wrench-C- with 5…50 Nm range (e.g. -V.A.G 1331-). t  Ensure that the spindle thread -A- moves smoothly. If necessary lubricate with grease -MOS 2-. t  If the thread is tight (e.g. due to dirt), the required clamping force for the hose clamp will not be attained although the specified torque is applied.

Tensioning small hose clamp on outer joint

Tensioning large hose clamp on inner joint

Driving off cover for inner joint

Pressing off inner joint –  Support ball hub when performing this step. –  First remove circlip with long nosed pliers. –  Loosen hose clamp and push bellows back. –  Drive cap off with drift. –  Press joint off. –  Support shaft.

Pressing on inner joint –  Carefully tension with tensioner -40 - 204 A-; do not damage the corrosion protection on the drive shaft.   Note Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive shaft. –  Press on joint to stop. –  Insert circlip.