Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ VW 426 Tube
• ◆ 40-204 A Tensioner
• ◆ 3340 Pliers

Dismantling

• ‒ → Open hose clamp.
• ‒ Open clamp on shaft and slide back joint protective bellows.

• ‒ → Open out metal tabs with a screwdriver and lever off cover.

• ‒ → Mark installation position of parts 1 . . . 3.

If the parts are not marked and when assembling, the components are not brought back to their previous installation position then it is possible that it will be noisy when driving.

A waterproof felt tipped pen is suitable for marking.

•      1 -     Joint
•      2 -     Triple roller star
•      3 -     Drive shaft

• ‒ Take O-ring -arrow- out of groove.
• ‒ Hold joint and take drive shaft out of vice.

• ‒ → Remove circlip.

•      1 -     Pliers (commercial type)
• or VW 161 A

• ‒ Insert drive shaft in press.
• ‒ → Hold drive shaft, then press triple roller star off drive shaft.
• ‒ Take off Triple roller star with rollers and place on a clean surface.
• ‒ Pull joint off shaft.
• ‒ Pull protective bellows off shaft.
• ‒ Clean shaft and housing.

Assembling

• ‒ Slide joint protective bellows onto shaft.
• ‒ Slide joint onto shaft.

Assembling triple roller star

• The chamfer on star faces towards shaft, this is used as an assembly aid.

• ‒ → Fit triple roller star onto shaft as per markings and press onto stop.
• ‒ Insert circlip, ensure seated correctly.
• ‒ Press 60 grammes of joint grease G 000 633, from repair set, into triple roller joint.
• ‒ Slide joint over rollers and hold.
• ‒ Press 60 grammes of joint grease G 000 633, from repair set, into the reverse side of the tripodic joint.
• ‒ Fit joint protective bellows.

• The ridge in the joint protective bellows must seat in the joint groove.

• ‒ Now take drive shaft out of vice and tension joint in vice.
• ‒ → Insert new seal -arrow- from repair set into groove.
• ‒ Fit new cover to joint.

• The drillings of the cover and joint must align.

• ‒ → Fit hose clip.