Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling drive shaft with VL90 or VL100 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 washer -VW 447 H-

t	Circlip pliers -VW 161 A-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Special pliers -V.A.G 1682-

t	Assembly tool -T10065-

t  Multi-purpose tool -VW 771-

t  Puller -T10382- 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 thrust washer 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 Assembling

Installation position of dished spring at inner joint 1 -  Dished spring

Pressing on inner constant velocity joint   Note Chamfer on internal circumference of ball hub (splines) must face contact shoulder on drive shaft.

Tighten clamp on outer joint –  Apply special pliers-V.A.G 1682- as shown in diagram. Ensure jaws of tool contact corners -arrows B- of clamp. –  Tighten clamp by turning spindle with a torque wrench (do not cant pliers).   Note t  Because a stainless steel boot clamp is required due to the hard material of the joint boot (compared to rubber), it is possible to tighten the clamp only with clamp tensioner -V.A.G 1682-. t  Torque setting: 25 Nm. t  Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g. torque wrench -V.A.G 1331-). t  Make sure thread of spindle -A- on pliers moves freely. Lubricate with MoS2 grease if necessary. 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 clamp on small diameter