Volkswagen Workshop Service and Repair Manuals

• Circlip
• ◆ Renew
• ◆ Remove and install with
  VW 161 a
• Gasket
• ◆ Renewing. Pull off protective foil and stick onto joint.
• Inner constant velocity joint
• ◆ Only renew complete
• ◆ Pressing off => Fig.2
• ◆ Pressing on => Fig.3
• ◆ Greasing
• ◆ Checking => Page 40-74
• Dished washer
• ◆ Inner øsplined
• ◆ Installation position: outer ø(concave side) contacts constant velocity joint
• Drive shaft, right (tube shaft)
• Drive shaft, left (solid shaft)

• Hose clip
• ◆ Renew
• ◆ Tensioning => Fig.4 and Fig.5
• Protective bellows
• ◆ Check for tears and chafing
• Hose clip
• ◆ Renew
• ◆ Tensioning => Fig.4 and Fig.5
• Dished washer
• ◆ Outer ø (concave side) contacts thrust washer
• Thrust washer
• Circlip
• ◆ Renew
• ◆ Insert in shaft groove
• Outer constant velocity joint
• ◆ Only renew complete
• ◆ Removing =>Fig.1
• ◆ Installing: drive onto shaft on to stop with plastic hammer
• ◆ Greasing => Page 40-65
• ◆ Checking => Page 40-72

• Self-locking 12-point nut
• ◆ Tightening
• ◆ Any paint residue and/or corrosion on thread of the outer joint must be removed before the nut is fitted.
• ◆ Renew each time after removing
• Socket head multi-point bolt,
  45 Nm
• Hose clip
• ◆ Renew
• ◆ Tensioning => Fig.4 and Fig.5
• Plate
• Protective bellows for inner constant velocity joint
• ◆ Check for tears and chafing
• ◆ Drive off with drift

→ Fig.1     Removing outer constant velocity joint

• ‒ Drive joint off drive shaft with a firm blow from an aluminium hammer.

→ Fig.2     Pressing off inner constant velocity joint

Notes:

• ◆ First drive bellows off with drift
• ◆ Support ball hub

→ Fig.3     Pressing on inner constant velocity joint

• ‒ Press on joint up to stop.
• ‒ Insert circlip.

Note:

Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive shaft.

→ Fig.4     Ventilating joint bellows

Often the bellows is pushed in when installing on the joint body. This creates a vacuum inside the bellows which draws a fold in (arrow) whilst driving. Therefore after fitting, lift the bellows at small diameter end to equalize pressure.

→ Fig.5     Tensioning outer joint hose clamp

• ‒ Fit pliers V.A.G 1682 as shown in illustration. When doing this ensure that the jaws of the pliers seat in the corners (arrow B) of the hose clip.
• ‒ Tension hose clamp by turning the spindle with a torque wrench (do not cant pliers).
  

Notes:

• ◆ Due to the hard material of the joint bellows (compared to rubber) and, due to this the necessary stainless steel hose clamp, it is only possible to tension the hose clamp with pliers V.A.G 1682.
• ◆ Tightening torque: 20 Nm.
• ◆ Use torque wrench -C- with 5...50 Nm range (e.g. V.A.G 1331).

• ◆ Ensure the the spindle -A- thread is not tight. If necessary lubricate with MOS 2 grease
• ◆ If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct tightening torque settings.

→ Fig.6     Tensioning inner joint hose clamp