Servicing drive shaft — AUDI

Special tools and workshop equipment required

3207 Pressure spindle
40-204 A Tensioner
VW 161 A Circlip pliers
VW 401 Pressure plate
VW 402 Pressure plate
VW 411 Press tool
VW 412 Press tool
VW 522 Support sleeve
V.A.G 1275 Hose clamp pliers

Quantities and type of grease

Constant velocity joints are filled with high-temperature grease.

=> Parts List

Grease · of which in:
Outer joint · Total quantity · Joint · Bellows
ø mm · [g] · [g] · [g]
89 · 90 · 40 · 50
Inner joint
ø mm
100 · 80 · 30 · 50

Re-grease joint if necessary on replacing boot.

Circlip
Always replace
Removing and fitting with circlip pliers VW 161 A => Fig.
4

Gasket
Replace; pull off backing and bond into joint

Inner constant velocity joint
OD: 100 mm
Replace only as complete assembly
Pressing off => Fig.
2
Pressing on => Fig.
3
Lubricating => Page
42-118
Checking => Page
42-130

Dished washer
Installation position => Fig.
6

Boot for inner constant velocity joint
Check for cracks and abrasion
Drive off with mandrel
Checking inner constant velocity joint if boot damaged => Page
42-130
Coat sealing surface with D 454 300 A2 before attaching to constant velocity joint
Before fitting, align screw holes of inner constant velocity joint and inner boot
On assembly, boot/drive shaft sealing surfaces must be free from grease

Drive shaft
Same length on left and right

Boot for outer constant velocity joint
Check for cracks and abrasion and replace if necesssary
Checking outer constant velocity joint if boot damaged => Page
42-127
On assembly, boot/drive shaft/joint sealing surfaces must be free from grease

Clamp
Replace
Tensioning => Fig.
1

Dished washer
Large ø (concave side) makes contact with thrust ring
Installation position => Fig.
5

Spacer ring (plastic)
Installation position => Fig.
5

Circlip
Replace
Insert in shaft groove

Outer constant velocity joint
OD: 89 mm
Replace only as complete assembly
Pressing off =>Fig.
7
Checking => Page
42-127
Installing: Drive onto shaft with plastic-headed hammer until circlip engages in annular groove of constant velocity joint
Lubricating => Page
42-118

Fig.1
Tensioning hose clamp or clamp

Fig.2
Pressing off inner constant velocity joint

Notes:

Use mandrel to drive off boot beforehand.
Support ball hub.

Fig.3
Pressing on inner constant velocity joint

Note:

Chamfer at ID of ball hub (splines) must face contact collar of drive shaft.

Press on joint as far as it will go.
Engage circlip.

Fig.4
Removing/fitting circlip

Fig.5
Installation position of spacer ring and dished washer (wheel end)

1 -
Dished washer
2 -
Spacer ring (plastic)

Fig.6
Fitting dished washer in correct position

Fig.7
Pressing off outer constant velocity joint

Clamp drive shaft with soft jaws in vice.
Detach clamp and push back bellows.
Screw pressure spindle -3207- with M14 thread into joint pin until constant velocity joint is pressed off drive shaft.