Golf Mk4
| IV - Repairing front drive shaft with triple roller joint AAR 2900 |
| Special tools and workshop equipment required |
| t | Thrust plate -VW 401- |
| t | Thrust plate -VW 402- |
| t | Press tool -VW 408 A- |
| t | Press tool -VW 411- |
| t | Tube -VW 416 B- |
| t | Thrust plate -VW 447 H- |
| 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- |
| t | Assembly tool -T10065- |
|
| Grease | of which in: | ||
| Outer joint | Total quantity | Joint | Boot |
| Ø mm | [g] | [g] | [g] |
| 90 | 100 | 50 | 50 |
| Inner joint | |||
| Ø mm | |||
| 124 | 140 | 70 | 70 |
|
| 1 - | Self-locking 12-point nut |
| q | Tightening → Chapter. |
| q | Remove any corrosion on thread of outer joint before fitting nut. |
| q | Renew each time after removing. |
| 2 - | Outer constant velocity joint |
| q | Renew only complete. |
| q | Removing → Fig.. |
| q | Installing: drive onto shaft with plastic hammer until compressed retaining ring seats. |
| q | Checking → Chapter. |
| q | Greasing → . |
| 3 - | Retaining ring |
| q | Renew each time after removing. |
| q | Insert in groove in shaft. |
| 4 - | Thrust washer |
| q | Installation position → Fig.. |
| 5 - | Dished spring |
| q | Installation position → Fig.. |
| 6 - | Clamp |
| q | Renew each time after removing. |
| q | Tighten with pliers -V.A.G 1682- → Fig.. |
| 7 - | Constant velocity joint boot |
| q | Check for splits and chafing. |
| q | Material: Hytrel (polyester elastomer). |
| 8 - | Clamp |
| q | Renew each time after removing. |
| q | Tightening → Fig.. |
| 9 - | Drive shaft |
| 10 - | Clamp |
| q | Renew each time after removing. |
| q | Tightening → Anchor. |
| 11 - | Triple roller joint boot |
| q | Check for splits and chafing. |
| 12 - | Clamp |
| q | Renew each time after removing. |
| q | Tightening → Anchor. |
| 13 - | Joint body |
| 14 - | Multi-point socket head bolt |
| q | M8 x 18; |
| Torque settings: → |
| 15 - | Rollers |
| 16 - | Triple roller star |
| The chamfer -arrow- points towards drive shaft splines. |
| 17 - | Retaining ring |
| q | Renew. |
| q | Insert in groove in shaft. |
| 18 - | O-ring |
| Is no longer required for assembly. |
| 19 - | Rectangular section seal |
| This oil seal is part of the repair set. It is not installed during manufacture. |
| No longer supplied as a spare part; instead, a new repair set is supplied. |
| 20 - | Cover |
| Will be destroyed when dismantled. |
| No longer required for assembly and is therefore not supplied as a spare part. |
| New cover is included in repair kit. |
