Audi Workshop Service and Repair Manuals

Servicing drive shaft (with 100 mm dia. inner constant velocity joint)

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 412-

t	Tensioner -40-204 A-

t	Support sleeve -VW 522-

t	Press tool -VW 411-

t	Hose clip pliers -V.A.G 1275-

Grease quantity and type Grease filling of constant velocity joints; Allocation → Electronic parts catalogue

	Grease quantity	of which in:
Outer joint	Total quantity	Joint	Boot
[mm]	[g]	[g]	[g]
88	90	40	50
Inner joint		Put in grease through ball bearing races
100	80

Regrease joint when renewing boot.

1 -

Cover

q	Drive off carefully with drift → Fig.

q	Always renew

q	Before fitting on constant velocity joint, coat sealing surface with D 454 300 A2 → Fig.

q	Align cover with bolt holes

2 -

Circlip

q	Use normal commercial circlip pliers when removing and installing

q	Always renew

3 -	Inner constant velocity joint

q	Outside diameter: 100 mm

q	Renew only as complete unit

q	Pressing off → Fig.

q	Pressing on → Anchor

q	Greasing → Anchor

q	Adhesive surfaces must be free of oil and grease

q	Grease splines on drive shaft lightly with grease used in joint when fitting joint onto drive shaft

4 -	Lock plate

5 -	Multi-point socket head bolt

q	For correct version refer to → Parts catalogue

q	Tightening torques:

M 8 bolt: 40 Nm

M10 bolt: 65 Nm

6 -	Boot with cap for inner constant velocity joint

q	With vent hole

q	Drive cap off carefully with drift

q	Always renew

q	Check inner constant velocity joint if boot is damaged → Chapter

q	Before fitting on constant velocity joint, coat sealing surface with D 454 300 A2 → Fig.

q	Align cover with bolt holes

q	Sealing surfaces (boot/drive shaft) must be free from grease when assembling

7 -	Drive shaft

8 -	Boot for outer constant velocity joint

q	Without vent hole

q	Check for splits and chafing, renew if necessary

q	Check outer constant velocity joint if boot is damaged → Chapter

q	Sealing surfaces (boot/drive shaft and boot/joint) must be free from grease when assembling

9 -

Hose clip

q	Always renew

q	Tightening → Fig.

10 -

Circlip

q	Always renew

q	For correct version refer to → Parts catalogue

q	Insert in groove on shaft

11 -	Outer constant velocity joint

q	Outside diameter: 88 mm

q	Renew only as complete unit

q	Driving off → Fig.

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

q	Circlip must fit in chamfer on joint when installing; guide with pliers if necessary

q	Greasing → Anchor

q	Grease splines on drive shaft lightly with grease used in joint when fitting joint onto drive shaft

12 -	Flange bolt

q	Always renew

q	Tightening torque → Item

Pressing off outer constant velocity joint –  Clamp drive shaft in vice using protective jaw covers. –  Loosen hose clip and push back boot. –  Drive constant velocity joint off drive shaft using a drift -A-. The drift must be positioned exactly on the spider of the constant velocity joint.

Installing joint –  Grease splines -A- on drive shaft lightly with grease used in joint before fitting joint body onto drive shaft. –  Fit circlip in groove on shaft.

–  Slide on constant velocity joint as far as circlip. –  Align circlip so that opening faces upwards -arrows-. –  Knock joint onto shaft with plastic hammer until circlip engages.

Tightening hose clip

Driving off cover from inner joint

Pressing off inner constant velocity joint –  Release circlip. –  Drive off boot with drift.   Note Support ball hub with thrust plate -VW 402-.

Pressing on inner constant velocity joint –  Grease splines -A- on drive shaft lightly with grease used in joint before fitting joint or triple roller spider onto drive shaft.

–  Press on joint as far as stop. For this step use support sleeve -VW 522-. –  Engage circlip.   Note Chamfer on internal diameter of ball hub (splines) must face drive shaft.

Coating sealing surface of cover and cap with D 454 300 A2 –  Apply sealant on clean surface of cover and cap (hatched area). Route continuous bead of sealant (2...3 mm Ø) around inside of holes -arrow-. –  Align cover and cap with bolt holes and drive or press onto joint. –  Remove surplus sealant immediately as it is pressed out.