Volkswagen Workshop Service and Repair Manuals

Repairing drive shaft

t	Grease filling high-temperature grease -G 052 133 A2-: Outer CV joint: 90 g, inner CV joint: 120 g

t	Greasing outer joint: press half of the grease into the joint and the other half evenly into the bellows.

t	Greasing inner joint: Press half of the grease into the joint from both sides, the other half evenly into the bellows.

t	Regrease joint if required when renewing boot.

1 -	Retaining ring

q

Renew.

q	Expand and compress with circlip pliers -VW 161 A-.

2 -

Gasket

q	Renewing. Pull off protective foil and stick into joint.

q	Only on 100 mm Ø constant velocity joints.

3 -	Inner constant velocity joint Ø 100 mm

q	For vehicles with output of 66 kW and above.

q	Different material for 16V vehicles.

q	Renew only complete.

q	Pressing off → Fig..

q	Pressing on → Fig..

q	Greasing → Chapter

q	Checking → Chapter

q	As of 08.89 also for vehicles over 62 kW.

4 -	Inner constant velocity joint Ø 94 mm

q	For vehicles with output up to 65 kW.

q	Renew only complete.

q	Pressing off → Fig..

q	Pressing on → Fig..

q	Greasing → Chapter

q	Checking → Chapter

5 -	Dished spring

q	Toothed in inner Ø

q	Installation position: larger Ø (concave side) contacts constant velocity joint.

6 -	CV joint boot for 100 mm Ø CV joint

q	With vent hole

q	Check for splits and chafing.

q	Installation position for left shaft → Fig.

q	Installation position for right shaft → Fig..

q	Coat cap sealing surface with sealant -D 454 300 A2-.

q	Drive off with drift.

7 -	CV joint boot for 94 mm Ø CV joint

q	Check for splits and chafing.

q	Drive off with drift.

8 -

Clamp

q

Renew.

q	Tensioning → Fig. and → Fig..

9 -

Hose clip

q	Renew, separate closed metal rings with metal saw.

q	Tensioning → Fig. and → Fig..

q	Modified as of 01.90 → Fig..

10 -	CV joint boot for 90 mm Ø CV joint

q	Check for splits and chafing.

q	Allow air to enter joint protective boot briefly to balance pressure before tightening small clamp in place → Fig..

11 -	CV joint boot for 81 mm Ø CV joint

q	Check for splits and chafing.

q	Allow air to enter joint protective boot briefly to balance pressure before tightening small clamp in place → Fig..

q	Modified as of 01.90 → Fig..

12 -	Outer constant velocity joint Ø 90 mm

q	For vehicles with output of 66 kW and above.

q	Different material for 16V vehicles.

q	Modification: As of 08.87 contact shoulder for wheel bearing modified → Fig..

q	Renew only complete.

q	Removing → Fig.

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

q	Greasing → Chapter

q	Checking → Chapter

13 -	Outer constant velocity joint Ø 81 mm

q	For vehicles with output up to 65 kW.

q	Modification: As of 08.87 contact shoulder for wheel bearing modified → Fig..

q	Renew only complete.

q	Removing → Fig.

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

q	Greasing → Chapter

q	Checking → Chapter

14 -	Retaining ring

q

Renew.

q	Insert in groove in shaft.

15 -	Thrust washer

16 -	Dished spring

q	Outer Ø (concave side) contacts thrust washer.

17 -	Drive shaft for vehicles with output of 66 kW and above

q	Constant velocity joint splines 4 mm longer than shafts for lower-output engines, measured from dished spring support to retaining ring groove.

q	Length of shaft → Fig..

q	As of 08.89 also installed in vehicles over 62 kW.

18 -	Drive shaft for vehicles with output up to 65 kW

q	Length of shaft → Fig..

q	As of 08.89 also installed in vehicles up to 59 kW.

19 -	Damper weight (two-piece)

q	Installed on right shaft in vehicles with 51 kW engines and vehicles with diesel engine.

q	Removing and installing → Fig.

q	Installation position → Fig..

20 -	Damper weight (one-piece)

q	Installed as of 04.88 (standard).

q	Use damper weight → Item as spare part.

q	Installation position → Fig..

Removing and installing right drive shaft damper weight The damper consists of two halves. Both halves are joined to one another by spring pins -arrow-. Installation position → Fig..   Note t  Before driving in spring pin, protect shaft paint finish against damage. t  Adhesive tape is applied on inner diameter to prevent axial movement. Before re-installing damper weight, check adhesive effect of adhesive tape. If necessary, renew adhesive tape or apply another adhesive.

Installation position of damper weight (In drive shafts with CV joint boot without vent bore) When installing damper weight -A-, prescribed installation position must be ensured. Adherence to dimension a = 4 mm, measured from conical part of shaft to damper weight, is necessary to do this.

Installation position of damper weight (In drive shafts with ventilated CV joint boot) When installing damper weight -A-, prescribed installation position must be ensured. Dimension a = 478 mm must be adhered to.   Note If damper weight is damaged, replace with two-piece damper weight.

CV joint with modified contact shoulder

As of 08.87	Dimension a = Ø 53 mm
Up to 08.87	Dimension a = Ø 50 mm

Previous drive shaft/outer CV joint version (small contact shoulder) must not be installed in vehicles as of model year 1988, as the CV joint-wheel bearing contact area is then too small. Previous drive shaft/outer CV joint version will be discontinued when consumed.

Removing outer joint Drive joint off drive shaft with a firm blow from an aluminium hammer.

Pressing off inner joint Support ball hub when performing this step.

Pressing on inner joint Press on joint to stop. Insert retaining ring.   Note Chamfer on the inner circumference of ball hub (splines) must face the contact shoulder of the drive shaft.

Installing CV joint boot on left drive shaft –  Vehicles with output of 66 kW and more: Before installing CV joint boot on drive shaft, mark dimension a = 17 mm with e.g. paint or adhesive tape. Under no circumstances should paint finish be damaged with a sharp tool.

Installing CV joint boot on right drive shaft –  Vehicles with output of 66 kW and above. The large diameter of vent chamber -A- must fit on the larger diameter. -B- = vent bore

Venting joint boot The boot is frequently pressed in when installed on the joint body. This creates a partial vacuum inside the boot which draws in a fold -arrow- when the car is driven. Therefore, after fitting boot, lift boot at small diameter end to equalise pressure.

Tension hose clip or clamp with hose clip pliers -V.A.G 1275-.

Modified CV joint boot and hose clip –  Apply clamp tensioner -V.A.G 1682- as shown in figure. Ensure jaws of tensioner contact corners -arrows B- of hose clamp. –  Tighten hose clip by turning spindle -A- with torque wrench (take care to keep clamp tensioner straight).   Note t  Hose clip can only be tensioned with clamp tensioner -V.A.G 1682-. t  Tightening torque: 25 Nm. t  Use torque wrench with setting range of 5…50 Nm (e.g. -V.A.G 1331-). t  Ensure that thread of tensioner spindle moves freely. If necessary lubricate with MoS2 grease. t  If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clip with the specified tightening torque. t  Tensioning hose clip at small diameter of boot is carried out in the same way.

Length of shaft

Gearbox version	Length dimension -a- (mm)				Remarks
	Left		Right
Manual gearbox 020 → Note and 02A	443		677.2		Left full shaft right tubular shaft
Manual gearbox 084 and 085	465		677.2		Left full shaft right tubular shaft
Automatic gearbox	443		677.2		Left full shaft right tubular shaft
Golf syncro manual gearbox 009 and 02C front axle, rear axle	443 543.6		513.5 404.5		Left/right full shaft left/right full shaft

1)  Drive shafts for GTI/GLI vehicles have 4 mm longer splines from contact shoulder for dished spring to groove for circlip.