Driveshaft, Servicing

Driveshaft, servicing

Special tools and workshop equipment required





^ VW 391 drive shaft fitting appliance
^ VW 401 Press plate
^ VW 402 Press plate
^ VW 407 Press tool
^ VW 408 A Press tool
^ VW 454 Press piece





^ VW 522 Support sleeve
^ 40 204 A Tensioner
^ VAG1275 Pliers
^ VAG1331 Torque wrench
^ VW 161 A Circlip pliers
^ 2 Kukko 18/0 Puller
^ 3 Kukko 17/1 Separating tool





Notes:
^ To obtain the quietest possible running, the entire driveshaft is balanced during manufacture. It is not possible to balance the entire driveshaft or the individual driveshaft sections using workshop equipment, therefore if a front or rear driveshaft section is damaged then the complete driveshaft must be replaced.
^ Keep driveshaft straight:, only store and transport fully extended.
^ Before removing, mark the positions of all parts in relation to each other. Reinstall in the same position otherwise imbalance will be excessive, creating rumbling noises and possibly damaging bearings.
1. Transmission with bevel box
2. 12 point collared bolt, 60 Nm
3. Flexible coupling with heat shield
4. Front driveshaft tube Do not damage centralizing sleeve and flange center seal.
5. Socket head bolt, 40 Nm
6. Lock plate
7. Tensioning clamp
^ Tensioning, Refer to Fig. 3
8. Constant velocity joint boot
^ Drive off with a drift before pressing CV joint off
^ Check for damage
9. Dished spring
^ Inner diameter serrated
^ Installation position: Large diameter lies against CV joint
10. Gasket
^ Replace
^ Pull off protective foil and stick onto joint.
11. Constant velocity joint
^ Pressing off, Refer to Fig. 1
^ Pressing on, Refer to Fig. 2
^ Greasing: Press 25g of G - 6.3 grease into joint from each side (50 g in total), when replacing boot re - grease joint if necessary
12. Circlip
^ Replace
^ Remove and install with circlip pliers VW 161 a
13. Hexagon bolt, 45 Nm
14. Washer
^ Always replace
15. Flange
^ Pulling off, Refer to Fig 4
^ Pulling on, Refer to Fig 5
16. Center bearing
^ Pulling off, Refer to Fig. 6
^ Installation position, Refer to fig. 7
^ Driving on, Refer to Fig. 8
17. Bolt, 25 Nm
18. Rear driveshaft tube
^ Do not damage centralizing sleeve and flange center seal when removing and installing.
19. Flexible coupling with vibration damper
20. Rear final drive





Fig. 1 Pressing constant velocity joint off





Fig. 2 Pressing constant velocity joint on

- Press on carefully.
- Tighten tensioner 40 04 securely, the driveshaft must not be pushed down within the tensioner, otherwise paint will be damaged.
- Repair paint damage as follows if necessary: Remove grease with Nitro thinner L 001 600. Apply 2 component acrylic paint (ALN 769 041 with hardener ALZ 009 001).





Fig. 3 Tensioning clamp on driveshaft
- When performing repairs, select correct clamp from Parts Supplier.





Fig. 4 Pulling flange off





Fig. 5 Pulling flange on





Fig. 6 Pulling center bearing off
- Rubber guide of center bearing must be cut through and metal casing removed.
- A Separating tool 12...75 mm e.g. Kukko 17/1
- B Puller, e.g. Kukko 18/0





Fig. 7 Installation position of center bearing
- The longer support - A - points to left when looking forward (arrow).





Fig. 8 Driving center bearing on
- Drive center bearing onto stop.