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 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	Pliers -V.A.G 1682-

t	Assembly tool -T10065-

Grease quantities and types Filling joints 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 -	12-point nut (self-locking)

q	Tightening → Chapter.

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

2 -	Right drive shaft (tubular shaft)

3 -	Multi-point socket head bolt

q	Specified torques → Anchor

4 -	Locking plate

5 -

Clamp

q

Renew.

q	Tightening → Fig.

6 -	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.

7 -	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.

8 -	Dished spring

q	Installation position → Fig.

9 -	Inner constant velocity joint

q	Renew only as complete unit

q	Pressing off → Fig.

q	Pressing on → Fig.

q	Greasing → .

q	Checking → Chapter

10 -

Seal

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.

11 -	Retaining ring

q	Remove and install using -VW 161 A-

12 -	Left drive shaft (solid shaft)

q

Renew.

q	Tightening → Fig.

13 -

Clamp

14 -

Boot

q	Check for splits and chafing

q	Material: Hytrel (polyester elastomer)

15 -	Balance weight

16 -

Clamp

q

Renew.

q	Use clamp tensioner -V.A.G 1682- to tighten → Fig.

17 -	Dished spring

q	Installation position → Fig.

18 -	Hexagon bolt

q

M10 x 28

q	Specified torques → Anchor

19 -	Protective cap

20 -	Thrust washer

q	Installation position → Fig.

21 -	Retaining ring

q

Renew.

q	Insert in groove in shaft

22 -	Outer constant velocity joint

q	Renew only as complete unit

q	Removing → Fig.

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

q	Greasing → .

q	Checking → Chapter

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 First drive off boot with drift.

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

Installation position of dished spring and thrust washer on outer joint 1 -  Dished spring 2 -  Thrust washer

Pressing on inner constant velocity joint –  Press joint on to stop. –  Install retaining ring.   Note Chamfer on internal circumference of ball hub (splines) must face contact shoulder on drive shaft.

Installation position of boot on left drive shaft Dimension “a” = 17 mm Before installing joint protective 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

Tighten clamp on outer joint –  Apply clamp tensioner -V.A.G 1682- as shown in figure. Ensure jaws of tool contact corners -arrows B- of clamp. –  Tighten hose clip by turning spindle -A- with torque wrench (take care to keep clamp tensioner 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 -C- (adjustment range 5 ... 50 Nm), 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, corrosion), the required clamping force for the hose clamp will not be attained although the correct torque is applied.

Tensioning clamp on inner joint/small diameter