Volkswagen Workshop Service and Repair Manuals

I - Repairing front drive shaft with constant velocity joint

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 411-

t	Tube -VW 416 B-

t	Thrust plate -VW 447 H-

Special tools and workshop equipment required

t	Circlip pliers -VW 161 A-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Pliers -V.A.G 1682-

t	Assembly tool -T10065-

Grease quantities and types Joints are filled with high-temperature grease. → Electronic parts catalogue (ETKA)

	Grease	of which in:
Outer joint	Total quantity	Joint	Boot
Ø mm	[g]	[g]	[g]
81	80	40	40
90	120	80	40
Inner joint
Ø mm
94	90	40	50
100	120	50	70

Regrease joint if required when renewing boot.

1 -	Self-locking 12-point nut

q	Tightening → Chapter.

q	Remove any corrosion on thread of outer joint before fitting nut.

q	Renew each time after removing.

2 -	Outer constant velocity joint

q	Renew only complete.

q	Removing → Fig..

q	Installing: drive onto shaft to stop using plastic mallet.

q	Greasing → .

q	Checking → Chapter.

3 -	Retaining ring

q

Renew.

q	Insert in groove in shaft.

4 -	Thrust washer

q	Installation position → Fig..

5 -	Dished spring

q	Installation position → Fig..

6 -

Clamp

q

Renew.

q	Tighten with pliers -V.A.G 1682- → Fig..

7 -

Boot

q	Check for splits and chafing.

q	Material: Hytrel (polyester elastomer).

8 -

Clamp

q

Renew.

q	Tightening → Fig..

9 -	Drive shaft

10 -

Clamp

q

Renew.

q	Tightening → Fig..

11 -	Boot for inner constant velocity joint

q	Material: Hytrel (polyester elastomer).

q	Without breather hole.

q	Check for splits and chafing.

q	Drive off constant velocity joint with a drift.

q	Coat sealing surface of constant velocity joint with -D 454 300 A2- before installing.

12 -	Boot for inner constant velocity joint

q	Material: rubber

q	With vent hole.

q	Check for splits and chafing.

q	Drive off constant velocity joint with a drift.

q	Installation position for left shaft → Fig.

q	Installation position for right shaft → Fig..

q	Coat sealing surface of constant velocity joint with -D 454 300 A2- before installing.

13 -	Locking plate

14 -	Multi-point socket head bolt

Torque settings: →

15 -	Dished spring

q	Installation position → Fig..

16 -	Inner constant velocity joint

q	Renew only complete.

q	Pressing off → Fig..

q	Pressing on → Fig..

q	Greasing → .

q	Checking → Chapter.

17 -

Gasket

q	Adhesive surface on constant velocity joint must be free of oil and grease!

q

Renew.

q	Pull off protective foil and stick into joint.

18 -	Retaining ring

q	Remove and install using -VW 161 a-.

19 -	Hexagon bolt, 35 Nm

20 -	Protective cap

Removing outer constant velocity joint –  Clamp drive shaft in vice using protective jaw covers. –  Fold back boot. –  Set puller -T10382- up so that smooth side of puller plate -T10382/1- points to spindles -T10382/2-. –  Assemble puller -T10382- complete with multi-purpose tool -VW 771-.

–  Pull constant velocity joint from drive shaft with puller -T10382- and multi-purpose tool -VW 771-. 1 -  Puller plate -T10382/1- 2 -  Spindles -T10382/2- Driving on outer constant velocity joint

Installation position of dished spring and spacer ring on outer joint 1 -  Dished spring 2 -  Thrust washer –  Install new retaining ring. –  If necessary, push new joint boot onto drive shaft. –  Knock onto shaft with plastic hammer until circlip engages.

Pressing off inner constant velocity joint   Note First drive off boot with drift.

Installation position of dished washer on inner joint 1 -  Dished spring

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 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 vent chamber -A- must sit on tube. B -  Vent hole

Tightening clamp on outer joint –  Apply clamp tensioner -V.A.G 1682- as shown in figure. Ensure that jaws of tool contact corners -arrows B- of boot clamp. –  Tighten clamp by turning spindle with a torque wrench (do not cant pliers).   Note t  The hard material of the boot (compared to rubber) necessitates the use of a stainless steel clamp which can be tightened only with clamp tensioner -V.A.G 1682-. t  Torque setting: 25 Nm. t  Use torque wrench -C- with 5...50 Nm range (e.g. -V.A.G 1331-). t  Ensure that the spindle thread -A- moves smoothly. If necessary lubricate with grease -MOS 2-. t  If the thread is tight (e.g. due to dirt), the required clamping force for the boot clamp will not be attained although the correct torque is applied.

Tightening inner joint hose clamp (smaller diameter)