Front Drive Shaft With Constant Velocity Joint, Servicing

Front Drive shaft with constant velocity joint, servicing
Special tools and equipment required





- VW401 Thrust plate
- VW 402 Thrust plate
- VW 408 A Press tool
- VW 41 1 Press tool
- VW447 H Press plate
- VW454 Press piece





Special tools and equipment required
- VW 161 A Circlip pliers
- VAG 1331 Torque wrench
- VAG 1332 Torque wrench
- VAG 1682 Tension clamp
- T10065 Assembly device








Grease quantity and type
Note: Constant velocity joints are packed with grease G 000 603:

Regrease joint, if necessary, when replacing the protective boot.
1. Hex key head bolt, 25 Nm
2. Heat shield
3. Circlip
^ Always replace
^ Remove and install with VW 161 a
4. Gasket
^ Replacing. Pull off protective foil and stick onto joint.
5. Inner constant velocity joint
^ Outer diameter 100 or 108 mm depending on engine/transmission combination
^ Only replace complete
^ Pressing off
^ Pressing on
6. Drive shaft (tube shaft)
7. Hose clip
^ Always replace
8. Protective boot
^ Check for tears and chafing
9. Hose clip
^ Always replace
^ Tensioning and
10. Dished washer
^ Outer diameter (concave side) contacts thrust washer
11. Thrust washer
12. Circlip
^ Always replace
^ Insert in shaft groove
13. Outer constant velocity joint
^ Only Replace complete
^ Removing
^ Installing: drive onto shaft on to stop with plastic hammer
14. Hex bolt
^ Changed to hex key head bolt
^ Replace each time after removing
^ Vehicle must be standing on ground when tightening
^ Tightening torque:
^ Bolt M14:
^ 15 Nm plus an additional 180° turn
^ Bolt M16:
^ 190 Nm plus an additional 180° turn
15. Multi-point socket head bolt
^ Tighten using diagonal sequence to 10 Nm
^ M 8 x 48; 40 Nm
^ M 10x48; 77 Nm
16. Plate
17. Protective boot for inner constant velocity joint
^ Check for tears and chafing
^ Drive off with drift
^ Before installing on constant velocity joint, coat sealing surface with D-3

Joint protective boots made from rubber are tightened with pliers VAG 1275.
The instructions in Fig. 1 are only for hose clamps made from stainless steel!





Fig. 1 Tightening hose clamp on outer joint
- Install tensioning clamp VAG 1682 as shown in illustration. Make sure that the jaws of the tension clamp seat in the corners (arrow B) of the hose clip.
- Tighten hose clamp by turning the spindle with a torque wrench (do not bend tensioning clamp).

Note:
^ The hard material of the joint boot (compared to rubber) makes it necessary to use a stainless steel hose clamp, it is only possible to tighten the hose clamp with tensioning clamp VAG 1682.
^ Tightening torque: 20 Nm.
^ Use torque wrench with 5 to 50 Nm range (e.g. VAG 1331).
^ Make sure the the spindle 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. 2 Pressing off outer constant velocity joint
- Clamp drive shaft in vice using vice clamps.
- Remove hose clip and slide back boot.
- Drive constant velocity joint off drive shaft using drift -A-.
- Drive must be applied exactly on star of constant velocity joint.

Driving joint on
- Drive onto shaft with plastic hammer until securing ring engages.





Fig. 3 Pressing off inner constant velocity joint
Note: First drive boot off with drift





Fig. 4 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. 5 Ventilating joint boot
- Only for joint protective boot of rubber
- Often the boot is pushed in when installing on the joint body. This creates a vacuum inside the boot which draws a fold in (arrow) while driving. Therefore after installing, lift the boot at small diameter end to equalize pressure.