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 locked with locking compound -D 185 400 A2- on vehicles with Plus running gear.

Removing and installing drive shaft:

t	Vehicles with basic running gear → Chapter.

t	Vehicles with Plus running gear → Chapter.

t	Greasing: outer constant velocity joint 100 g G-6.3, inner constant velocity joint 110 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 -

Circlip

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.

3 -	Inner constant velocity joint, 100 mm Ø

q	Renew only complete.

q	Pressing off → Fig..

q	Pressing on → Fig..

q	Greasing → Chapter.

q	Checking → Chapter.

4 -	Dished spring

q	Splined on internal Ø.

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

5 -	Joint protective boot for 100 mm Ø constant velocity joint

q	Rubber version.

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.

6 -	Drive shaft

q	Left full shaft (not illustrated).

q	Right tubular shaft.

7 -

Clamp

q

Renew.

q	Tensioning → Fig. and → Fig..

8 -	Joint protective boot for 90 mm Ø constant velocity joint

q	Polyester elastomer version.

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..

q	Installation position for left shaft, wheel side → Fig. and → Fig..

q	Installation position for right shaft, wheel side → Fig..

9 -

Clamp

q

Renew.

q	Tensioning → Fig. and → Fig..

10 -	Dished spring

q	Outer Ø (concave side) contacts thrust washer.

11 -	Thrust washer

12 -

Circlip

q

Renew.

q	Insert in groove in shaft.

13 -	90 mm Ø outer constant velocity joint

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 -	90 mm Ø outer constant velocity joint

q	For vehicles with 16V or VR6 engine.

q	Larger diameter tapered splines.

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.

15 -	Vibration damper

q	Removing and installing → Fig..

q	Installation position → Fig..

q	Available as replacement part.

q	Is only installed on right tubular drive shaft. Exception: vehicles with 85 kW engine and 02C manual gearbox, only installed on left solid drive shaft.

16 -

Clamp

q

Renew.

q	Tensioning → Fig. and → Fig..

17 -	Support ring

q	Only on rubber versions of joint protective boots.

q	Only gearbox side → Electronic parts catalogue “ETKA”.

18 -	Joint protective boot for 100 mm Ø constant velocity joint

q	Polyester elastomer version.

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..

19 -	Protective cap

20 -	Hexagon bolt, 35 Nm

Removing and installing vibration damper The damper consists of two halves. Both halves are joined to one another by spring pins -arrow-. Installation position → Fig..   Note t  Only replace vibration damper with drive shaft removed t  Before driving in spring pin protect shaft paint finish against damage. t  To prevent axial movement apply adhesive tape or a suitable adhesive to internal diameter .

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

Dimension “a” =		521 ± 1 mm right shaft
		264 ± 1 mm left shaft (if vibration damper is fitted)

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 joint protective boot on left drive shaft (rubber version on gearbox side) Dimension -a- = 17 mm   Note 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 joint protective boot on right drive shaft, gearbox side 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 clamp on larger diameter –  Apply clamp tensioner -V.A.G 1682- as shown in figure. Ensure jaws of tool lie in 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 with 5...50 Nm range (e.g. -V.A.G 1331-). t  Make sure thread of spindle on clamp tensioner 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 smaller diameter inner joint hose clip

Installation position of joint protective boot on left drive shaft, wheel side: shaft Ø 27 mm Tolerance area -a- for boot seating: 1/2 to 11/2 indentations visible on end of boot.   Note These tolerances also apply for the installation position of the joint protective boot (polyester elastomer version) on gearbox side of left drive shaft.

Installation position of joint protective boot on left drive shaft, wheel side: shaft Ø 22 mm Installation position of boot: boot lies against shoulder -arrow- on drive shaft.

Installation position of joint protective boot on right drive shaft, wheel side Tolerance area -a- for boot seating: from contact with taper to 1/2 an indentation visible.