SEAT Workshop Service and Repair Manuals

Dismantling and assembling drive shaft with VL107 constant velocity joint

Special tools and workshop equipment required

t	Tightening plate -VW 401-

t	Tightening plate -VW 402-

t	Die -VW 408 A-

t	Support sleeve -VW 522-

t	Tensioner -40 - 204 A-

t	Clamp tensioner -V.A.G 1682-

t  Torque wrench -V.A.G 1331-

t  Multipurpose tool -VW 771-

t  Pulling device -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 –  Install new retaining ring. –  If necessary, push new joint boot onto drive shaft. –  Knock onto shaft with plastic hammer until circlip engages.

Driving off cover from inner joint –  Remove the securing ring. –  Remove both clamps and slide boot towards outer joint. –  Drive off boot with drift.

Pressing off inner constant velocity joint Assembling

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

–  Coat sealing surface of cover with -D 454 300 A2-. –  Apply a continuous bead of sealant with a 2 ... Ø 3 mm to 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 any excess sealant.

Tighten clamp on outer joint –  Apply special pliers-V.A.G 1682- as shown in diagram. Ensure that the edges of the tool fit into the corners -arrows B- of the clamp. –  Tighten clamp by turning spindle with a torque wrench (do not cant pliers).   Note t  Due to the hard material of the protective boot (compared to rubber) and the necessity of using a stainless steel clamp, it is only possible to tension the clamp with clamp tensioner -V.A.G 1682-. t  Tightening 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 clamp will not be attained although the specified tightening torque is applied.

Tightening clamp on small diameter