Volkswagen Workshop Service and Repair Manuals

Repairing drive shaft

Drive shafts on vehicles with Plus running gear have shorter and finer splines on the outer joint. A 12-point nut is used to secure to wheel bearing.

The splines of the outer joint and the wheel hub are bonded with locking fluid -D 185 400 A2-.

Removing and installing drive shaft for vehicles with Plus running gear → Chapter.

t	Quantity of grease for vehicles up to 48 kW: 90 g G 6.3 on outside and inside

t	Quantity of grease for vehicles with 55 kW and above:

t	Outside: 110 g G 6.3

t	Inside: 120 g G 6.3

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 and the other half evenly into the bellows.

t	Regrease joint if required when renewing boot.

1 -	Retaining ring

q

Renew

q	Remove and install with circlip pliers -VW 161 A-.

2 -

Gasket

q	Renew: Pull off protective foil and stick onto joint. Only 100 mm Ø constant velocity joints.

Modification

q	As of 08.93 also on constant velocity joints with 90 mm Ø.

3 -	Inner constant velocity joint 100 mm Ø for vehicles with output of 55 kW and above

q	Renew only complete.

q	Pressing off → Fig..

q	Pressing on → Fig..

q	Greasing → Chapter

q	Checking → Chapter

4 -	Inner constant velocity joint 94 mm Ø for vehicles with output up to 48 kW

q	Pressing off → Fig..

q	Pressing on → Fig..

q	Greasing → Chapter

q	Checking → Chapter

5 -	Dished spring

q	Splines in inner diameter.

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

6 -	Joint protective boot for 100 mm Ø constant velocity 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 with D3.

q	Drive off with drift.

7 -	Joint protective boot for 94 mm Ø constant velocity 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

q	Tensioning → Fig. and → Fig..

10 -	Joint protective boot for 90 mm Ø constant velocity 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 -	Joint protective boot for 81 mm Ø constant velocity 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..

12 -	Outer constant velocity joint 90 mm Ø for vehicles with output of 55 kW and above

q	Renew only complete.

q	Removing → Fig.

q	Installing: drive onto shaft with plastic hammer until compressed retaining ring seats.

q	Greasing → Chapter

q	Checking → Chapter

13 -	Outer constant velocity joint 81 mm Ø for vehicles with output up to 48 kW

q	Renew only complete.

q	Removing → Fig.

q	Installing: drive onto shaft with plastic hammer until compressed retaining ring 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 55 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.

18 -	Drive shaft for vehicles with output up to 48 kW

19 -	Damper weight

q	Installation position → Fig..

20 -	Constant velocity joint boot 94 and 100 mm Ø

q	Fitted as of 01.93.

21 -

Hose clip

q	Tightening → Fig..

Installation position of vibration damper When installing vibration damper -A- note correct installation position. Ensure dimension “a” is maintained.

Dimension “a” mm	Engine
541 ± 1	1.8 l - 55 kW
	1.8 l - 66 kW
	1.9 l - 48 kW
	1.9 l - 55 kW
	2.0 l - 85 kW
	2.0 l - 110 kW
525 ± 1	1.9 l - 47 kW
	1.9 l - 66 kW

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

Pressing off inner constant velocity joint   Note t  First drive bellows off with drift. t  Support ball hub.

Pressing on inner constant velocity 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.

Installation position of boot on left drive shaft Dimension -a- = 17 mm   Note Before installing boot on drive shaft, mark dimension -a- with, e.g. paint or adhesive tape. Under no circumstances should paint finish be damaged with a sharp tool.

Installation position of boot on right drive shaft The large diameter of vent chamber -A- must fit on the larger diameter. B -  Vent hole

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.

Tightening hose clips on outer joint –  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 with torque wrench (take care to keep pliers straight).   Note t  Due to the hard material of the CV joint boot (as opposed to rubber) and the stainless steel hose clip which is required as a result, this can only be tensioned using a clamp tensioner -V.A.G 1682-. t  Torque setting: 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.

Tensioning hose clips on inner joint (as of 01.93)