Volkswagen Workshop Service and Repair Manuals

Assembling –  Slide small clamp for joint boot onto shaft. –  Slide boot onto shaft. –  Push joint body onto shaft. Assembling triple roller star The chamfer on the star faces the shaft. It serves as an assembly aid.

–  Fit triple roller star onto shaft and press on to stop. –  Ensure that pressure does not exceed 3.0 t. –  If necessary, coat splines of drive shafts and triple roller star with lubricating paste -G 052 142 A2-. –  Insert retaining ring, ensuring that it is seated correctly. –  Fit rollers onto triple roller star according to markings. –  Slide joint body over rollers and hold. –  Press 70 grammes of drive shaft grease from repair set into triple roller joint. –  Pack 70 grammes of drive shaft grease, from repair set, into the reverse side of triple roller joint and in protective boot.

–  Insert O-ring -3- from repair kit in groove of triple roller joint -4-. 1 -  Retaining ring 2 -  Cover from repair kit 3 -  O-ring 4 -  Triple roller joint –  Insert drive shaft in press.

–  Press cover -1- into triple roller joint until retaining ring can be inserted. –  Insert retaining ring, ensuring that it is seated correctly. Retaining ring must engage audibly. –  Install joint boot.

–  Position triple roller joint roughly in the centre of normal travel, see distance between min. and max. –  Hold triple roller joint in this position and lift up protective boot -arrow-.

–  Fit clamp. In this way, any vacuum pressure that may have been formed within the boot can escape.   Note To make it easier to insert the multi-point socket-head bolts when installing the drive shaft, position ear -arrow A- of clamp between mounting flanges -arrows B- of joint body.

–  Tighten clamp with pliers -V.A.G 1275-.

–  Tighten clamp with pliers -V.A.G 1275-.