Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling drive shaft with VL107 constant velocity joint

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Support sleeve -VW 522-

t	Tensioner -40 - 204 A-

t	Special pliers -V.A.G 1682-

t  Torque wrench -V.A.G 1331-

t  Multi-purpose tool -VW 771-

t  Puller -T10382- Removing outer constant velocity joint –  Clamp drive shaft in vice using protective jaw covers. –  Fold back boot. –  Set puller -T10382- up so that smooth side of puller plate -T10382/1- points to spindles -T10382/2-. –  Assemble puller -T10382- complete with multi-purpose tool -VW 771-.

–  Pull constant velocity joint from drive shaft with puller -T10382- and multi-purpose tool -VW 771-. 1 -  Puller plate -T10382/1- 2 -  Spindles -T10382/2- Driving on outer constant velocity joint

Installation position of dished spring and thrust washer on outer joint 1 -  Dished spring 2 -  Thrust washer –  Knock onto shaft with plastic hammer until circlip engages.

Driving off cover for inner joint –  Remove retaining ring. –  Remove both clamps and slide boot towards outer joint. –  Use drift to drive off boot.

Pressing off inner constant velocity joint Assembling

Installation position of dished spring at inner joint 1 -  Dished spring

Pressing on inner constant velocity joint –  Press joint on to stop. –  Install retaining ring.

–  Coat sealing surface of cover with -D 454 300 A2-. –  Apply an unbroken bead of sealant 2 ... 0.3 mm Ø onto clean surface of cover in area of inner holes -arrow-.

–  Using bolts -arrows-, align new cover in relation to bolt holes. The alignment must be very accurate, because no further alignment is possible once the part has been hammered on. –  Drive on cover using a plastic hammer. –  Wipe off surplus sealant.

Tighten clamp on outer joint –  Apply special pliers-V.A.G 1682- as shown in diagram. Ensure jaws of tool contact corners -arrows B- of clamp. –  Tighten clamp by turning spindle with a torque wrench (do not cant pliers).   Note t  Because a stainless steel boot clamp is required due to the hard material of the joint boot (compared to rubber), it is possible to tighten the clamp only with clamp tensioner -V.A.G 1682-. t  Specified torque: 25 Nm. t  Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g. torque wrench -V.A.G 1331-). t  Make sure thread of spindle -A- on pliers moves freely. Lubricate with MoS2 grease if necessary. t  If the thread is tight (e.g. due to dirt), the required clamping force for the clip will not be attained although the correct torque is applied.

Tightening clamp on small diameter Checking outer constant velocity joint → Chapter Checking inner constant velocity joint → Chapter Checking function of constant velocity joint →