Skoda Workshop Service and Repair Manuals

Repairing drive shaft with CV joint Special tools and workshop equipment required t  Circlip pliers, e.g. -VW 161 A- t  Pressure plate -MP 3-406- t  Pressure plate -MP 3-407- t  Pressure spindle -MP 3-448- t  Strutting bushing -MP 6-428- t  Tensioner -MP 6-429- t  Tensioning pliers, e.g. -V.A.G 1682- t  Workshop press, e.g. -V.A.G 1290 A-   Note t  Assignment → Electronic Catalogue of Original Parts t  Grease joint if necessary, when replacing the joint boot. t  Spread the grease mass evenly in 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 → Chapter

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

t	Material: Hytrel (Polyelastomere)

t	inspect for tears and chafing points

7 -	Open warm-type clamp

t

replace

t	tensioning → Fig.

8 -	Drive shaft (solid shaft)

t	Assignment → Electronic Catalogue of Original Parts

9 -

39 Nm

t

M8 x 48

10 -

Shim

11 -	Open warm-type clamp

t

replace

t	tensioning → Fig.

12 -	Joint boot for inner CV joint

t	Material: Hytrel (Polyelastomere)

t	inspect for tears and chafing points

t	remove with a drift

13 -	Disc spring

t	Fitting position → Fig.

14 -	Inner CV joint

t	must be replaced completely

t	pressing off → Fig.

t	pressing on → Fig.

t	grease → Anchor

t	check → Chapter

15 -

Gasket

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

t

replace

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

16 -

Circlip

t

replace

t	remove and install with sprung pliers, e.g. -VW161 A-

Grease quality and grease quantity   Note The CV joints are filled with grease for operating at normal temperatures e.g. -N 052 738.00-.

	Grease	of which in:
Outer joint	Total amount	Joint	Joint boot
Ø mm	[g]	[g]	[g]
90	90	40	40
Inner joint
100	120	50	70

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

Pressing out the inner CV joint   Note t  First of all drive off joint boot with a drift. t  Support ball hub.

Fitting position of the disc spring at inner joint 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   Note Chamfer on inner diameter of the ball hub (serration) must point towards the bearing collar of the drive shaft. –  Press the joint up to the stop. –  Insert the circlip.   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: 20 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.

Tighten the open warm-type clamp on the outer joint (at the large 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

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