Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling drive shaft

Special tools and workshop equipment required

t	Thrust piece -T10049-

t	Puller -T10382-

t	Thrust piece -T10421-

t	Multi-purpose tool -VW 771-

t	Torque wrench -V.A.G 1331-

t	Special pliers -V.A.G 1682-

t	Three arm puller -Kukko 45-1-

Carry out the following work: Removing outer constant velocity joint –  Clamp drive shaft in vice using protective jaw covers. –  Open hose clip. –  Fold back bellows. –  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 –  Install new retaining ring. –  If necessary, push new joint boot onto drive shaft. –  Drive constant velocity joint onto shaft using plastic hammer until circlip engages.

Tightening new clamp on constant velocity joint –  Position clamp tensioner -V.A.G 1682- as shown in diagram. Ensure jaws of tensioner lie in corners -arrows B- of clamp. –  Tighten clamp by turning spindle with a torque wrench (do not cant pliers).   Note t  Due to the hard material of the protective boot (compared to rubber) and the necessity of using a stainless steel clamp, it is only possible to tension the clamp with clamp tensioner -V.A.G 1682-. t  Specified torque: 25 Nm. t  Use torque wrench -C - with setting range of 5 ... 50 Nm (e.g. torque -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 clamp will not be attained although the specified tightening torque is applied.

Tightening new clamp on small diameter –  Position clamp tensioner -V.A.G 1682- as shown in diagram. Ensure jaws of tensioner lie in corners -arrows B- of clamp. –  Tighten clamp by turning spindle with a torque wrench (do not cant pliers).   Note t  Due to the hard material of the protective boot (compared to rubber) and the necessity of using a stainless steel clamp, it is only possible to tension the clamp with clamp tensioner -V.A.G 1682-. t  Specified torque: 25 Nm. t  Use torque wrench -C - with setting range of 5 ... 50 Nm (e.g. torque -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 clamp will not be attained although the specified tightening torque is applied.

Make sure that deflector ring -1- is clipped completely onto outer joint.   Note t  The lugs of deflector ring -1- must face towards outer joint. t  Deflector ring -1- must lie on contact surface of outer joint -arrow-.   Note

If deflector ring -1- is not positioned correctly or if it fell off outer joint, it must be driven onto outer joint to stop using thrust piece -T10049-. Dismantling –  Unfasten both clamps on inner joint and push back boot. –  Pull joint body off drive shaft.

–  Remove circlip -1-.

–  Pull triple roller star -1- off drive shaft using a three arm puller, e.g. -Kukko 45-1--2-. –  Pull boot off shaft. –  Clean shaft, joint body and groove for seal. Assembling –  Push small hose clip for boot onto shaft. –  Push joint boot onto shaft.

–  Fit triple roller star -1- onto drive shaft -2-.   Note Ensure that chamfer -arrow- of triple roller star -1- faces towards drive shaft -2-.

–  Drive triple roller star -1- onto drive shaft using thrust piece -T10421--2-.

–  Insert circlip -1-, ensuring that it is seated correctly. –  Press half the drive shaft grease from the repair kit into the triple roller joint. –  Slide joint body over rollers and hold. –  Press the other half of the drive shaft grease from the repair kit into the back of the triple roller joint. –  Install joint boot. –  Tighten clamp on small diameter → Fig.. –  Tighten new clamp on constant velocity joint → Fig..