Overhaul

Driveshaft, through 29 June 2007

• The entire driveshaft was balanced during manufacture In order to achieve the quietest possible running. It is not possible to balance the entire driveshaft or the individual driveshaft tubes with shop equipment. The entire driveshaft must always be replaced if the front or rear driveshaft tubes are damaged.

• Do not kink the driveshaft, only store and move it when fully extended.

• Mark the position of all the parts to each other before removing them. Install in the same position otherwise the imbalance will be excessive and the bearings could get damaged causing rumbling noises.

Special tools, testers and auxiliary items required

• Puller (VW 391)

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 407)

• Punch (VW 408 A)

• Driving Sleeve (VW 244 b)

• Sleeve-Press Tool (VW 522)

• Press Block (40-204 A)

• Hose Clamp Pliers (V.A.G 1275)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Circlip Pliers (VW 161 A)

• Kukko Puller (18/0)

• Kukko Separating Tool 12-75 mm (17/1)

• Thrust Piece (40-105)

• 2 Arm Puller Kukko 20/10 (20/10)

• Stop Plate (T10108/1)

Removing the CV Joint





Installing the CV Joint





- Install carefully.

- Tighten the press block (40-204 A) , the driveshaft must not be pressed downward in the press block (40-204 A) , otherwise there may be damage to the paint.

- Fix any paint damage.

Tensioning the Clamp





Rear Driveshaft Tube, Clamping in a Vise using the Stop Plate (T10108/1)





- Secure the stop plate (T10108/1) to the driveshaft flexible disc.

- Place the nuts - B - on the bolts - A - between the stop plate (T10108/1) and flexible disc.

A M10 x 70 mm bolts with nuts
B M12 nuts

Removing the Flange





Installing the Flange





Removing the Intermediate Bearing





- Tension the separating device - A - with the straight sides of the tool behind the intermediate bearing.

- Then position the 2 arm puller - B - on the separating device.

- Remove the intermediate bearing from the driveshaft.

A Separating device 12 to 75 mm, for example, Kukko separating tool 12-75 mm (17/1)
B Two arm puller, for example, 2 arm puller Kukko 20/10 (20/10)

Intermediate Bearing, Installed Position





Dimension - a - = 49 mm

Dimension - b - = 45.5 mm

• The larger distance - a - measured from the center of the hole - arrow 1 - to the outer edge of the hole - arrow 2 - must face the flexible disc with the vibration damper (in the reverse direction of travel).

Intermediate Bearing, Installing





- Install the intermediate bearing.

Flexible Disc with Vibration Damper, Installed Position





The brace on the outer diameter - arrows - faces away from the driveshaft tube.