Skoda Workshop Service and Repair Manuals

Repairing drive shaft with outer and inner CV joint VL 3700 Special tools and workshop equipment required t  → Chapter   Note t  Assignment → Electronic Catalogue of Original Parts t  Grease joint if necessary, when replacing the joint boot.

1 -	Outer CV joint

t	must be replaced completely

t	removing → Fig.

t	install: drive onto the shaft with a plastic hammer until the compressed circlip expands

t	grease → Anchor

t	check → Chapter

2 -

Circlip

t

replace

t	insert into the groove at the shaft

3 -	Thrust ring

t	Fitting position → Fig.

4 -	Disc spring

t	Fitting position → Fig.

5 -	Open warm-type clamp

t

replace

t	tension with tensioning pliers, e.g. -V.A.G 1682-, → Fig.

6 -	Joint boot for outer CV joint

t	Material: Hytrel (Polyelastomere)

t	inspect for tears and chafing points

t	Fitting position for the left shaft → Fig.

t	Fitting position for the right shaft → Fig.

t	Assignment → Electronic Catalogue of Original Parts

7 -	Open warm-type clamp

t

replace

t	tensioning → Fig.

8 -	Drive shaft

t	Assignment → Electronic Catalogue of Original Parts

9 -	Joint boot for inner CV joint

t	Material: Arnitel (Polyelastomere)

t	inspect for tears and chafing points

t	Fitting position for the left shaft → Fig.

t	Fitting position for the right shaft → Fig.

t	Assignment → Electronic Catalogue of Original Parts

10 -	Open warm-type clamp

t

replace

11 -

Cover

t	remove from CV joint with drift

t	before installation coat the sealing surface of the cap with sealant -D 454 300 A2-

t	The sealing surface must be free of oil and grease!

12 -	Inner CV joint

t	must be replaced completely

t	pressing out → Fig.

t	pressing on → Fig.

t	grease → Anchor

t	check → Chapter

t	Assignment → Electronic Catalogue of Original Parts

13 -

Circlip

t

replace

t	remove with circlip pliers, e.g. -VW 161A-,

14 -	Fillister head screw with internal serrations

t	replace after each removal

t	initially tighten to 10 Nm, subsequently tighten crosswise to final torque:

M8 x 48 = 20 Nm + 180°

M10 x 52 = 50 Nm + 45°

t	Assignment → Electronic Catalogue of Original Parts

15 -

Shim

t	Assignment → Electronic Catalogue of Original Parts

16 -

Gasket

t	The adherend on the inner CV joint must be free of grease and oil!

t

replace

t	Remove the protective foil from the gasket and stick it into the inner joint

t	Assignment → Electronic Catalogue of Original Parts

17 -

Cover

t	remove from CV joint with drift

t	before installation coat the sealing surface of the cap with sealant -D 454 300 A2-

t	The sealing surface must be free of oil and grease!

Grease quality and grease quantity   Note The outer joints of the drive shaft are filled with: –  Grease for operating at normal temperatures part no.: -G 052 738 A2- –  Grease from the relevant repair kit –  High temperature grease, part no.: -G 052 133 A2-, or part no.: -G 052 133 A3- t  The inner joints of the drive shaft must only be filled with high temperature grease from the relevant repair kit or with grease part no.: -G 052 133 A2-, or part no.: -G 052 133 A3- → electronic catalogue of original parts Grease quantity → Anchor

Removing outer CV joint –  Drive off joint boot with a drift. –  Drive off the drive shaft with a strong blow of a plastic hammer.

Pressing out the inner CV joint   Note Support ball hub

Fitting position of the disc spring on the outer joint (gearbox side) -1- Disc spring

Fitting position of the disc spring and thrust ring on the outer joint -1- Disc spring -2- Thrust ring

Pressing in the inner CV joint –  Press the joint up to the stop. –  Insert the circlip.   Note Chamfer on inner diameter of the ball hub (serration) must point towards the bearing collar of the drive shaft.

Fitting position of the joint boot for the inner CV joint Ø 100 mm on the left shaft Dimension -a- = 17 mm   Note Mark the dimension -a- before installing the joint boot on the drive shaft, e.g. using colour or adhesive tape. Under no circumstances the paintwork must be damaged with a sharp object.

Fitting position of the joint boot for the inner CV joint Ø 100 mm on the right shaft The ventilation chamber -A- must be located on the large pipe diameter. -B- Ventilation hole.

Tighten the open warm-type clamp on the outer joint (at the large diameter)   Note t  In view of the hard material (as opposed to rubber) of the joint boot, which requires the use of a stainless steel open warm-type clamp, the latter can only be correctly tightened with tensioning pliers, e.g. -V.A.G 1682-. t  Tightening torque: 25 Nm. t  Use a torque wrench. t  Make sure the thread of spindle -A- of the tensioning pliers is smooth. If necessary grease with grease, e.g. molykote MoS2. t  If it is not smooth, e.g. if the thread is dirty, the necessary clamping force of the open warm-type clamp is not reached at the given torque. –  Position the tensioning pliers, e.g. -V.A.G 1682-, as shown in the fig. Make sure the cutting edges of the pliers are positioned in the corners (-arrows B-) of the open warm-type clamp. –  Tighten the open warm-type clamp by turning the spindle with a torque wrench (do not tilt the pliers during this process). -A- Spindle of tensioning pliers -B- Cutting edges of tensioning pliers

Tighten the open warm-type clamp on the outer joint (small diameter) –  Position the tensioning pliers, e.g. -V.A.G 1682-, as shown in the fig. Make sure the cutting edges of the pliers are positioned in the corners (-arrows B-) of the open warm-type clamp. –  Tighten the open warm-type clamp by turning the spindle with a torque wrench (do not tilt the pliers during this process). -A- Spindle of tensioning pliers -B- Cutting edges of tensioning pliers -C- Torque wrench

Tighten the open warm-type clamp on the inner joint –  Position the tensioning pliers, e.g. -V.A.G 1682-, as shown in the fig. Make sure the cutting edges of the pliers are positioned in the corners (-arrows B-) of the open warm-type clamp. –  Tighten the open warm-type clamp by turning the spindle with a torque wrench (do not tilt the pliers during this process). -A- Spindle of tensioning pliers -B- Cutting edges of tensioning pliers -C- Torque wrench

Fitting position of the joint boot for the outer CV joint Ø 90 mm on the left shaft The sealing surface of the joint boot must rest up to the stop on the shoulder of the shaft

Fitting position of the joint boot for the outer CV joint Ø 84 mm on the left and right shaft On the drive shaft, 1 to 1 1/2 groove must be visible   Note The condition mentioned above regarding the fitting position is also valid for the joint boot for the inner CV joint Ø 94 mm.

Fitting position of the joint boot for the inner CV joint at the left and right shaft

Fitting position of the joint boot for the outer CV joint at the left shaft

Fitting position of the joint boot for the outer CV joint at the right shaft