Servicing drive shaft with triple roller joint — AUDI

Note:

For vehicles with TDI and 6-cyl. engine as well as all models with automatic gearbox.

Grease fill of joints

Grease · Outer joint ø · Inner joint
88 mm · 98 mm · 130 mm
Total quantity · / 90 g 1) · / 120 g 2) · / 140 g 3)
In joint · 40 g · 80 g · 70 g
In boot · 50 g · 40 g · 70 g

1)
Grease G 000 603

2)
Grease G 000 633

3)
Grease G 000 605

Re-grease joint if necessary on replacing boot.

Hexagon collared bolt
Replace
M14: 115 Nm + further 1/2 turn (180°)
M16: 190 Nm + further 1/2 turn (180°)
Vehicle must be standing on its wheels when slackening off and tightening (danger of accident)

Boot
Rubber or Hytrel

=> Parts List

Check for cracks and abrasion
Before tensioning clamps, briefly lift rubber boot for pressure equalisation=> Fig.
40-34

Large clamp
Different versions; assignment

=> Parts List

Replace
Tensioning clamp for rubber boot
=> Fig.
40-34
Tensioning large stainless-steel clamp for Hytrel boot=>Fig.
40-35

Drive shaft
Small clamp
Different versions; assignment

=> Parts List

Replace
Tensioning for all versions => Fig.
40-35

Joint element

Multi-point socket-head bolt, 70 Nm
Triple roller star
Chamfer -arrow- faces drive shaft splines
Installation position => Page
40-39

Circlip
Replace
Insert in shaft groove

O-ring
Replace
Contained in repair set

Cover
Destroyed on removal
Repair set contains modified cover

Large clamp
Different versions; assignment

=> Parts List

Replace
Tensioning => Fig.
40-34

Boot for triple roller joint
Small clamp
Replace
Tensioning
=> Fig.
40-35

Dished washer
Installation position => Fig.
40-33

Spacer ring (plastic)
Installation position => Fig.
40-33

Circlip
Replace
Insert in annular shaft groove before assembly (not visible with joint fitted)

Outer constant velocity joint
Different versions; assignment

=> Parts List

Replace only as complete assembly
Pressing off =>Fig.
40-33
Installing:

Use plastic-headed hammer to drive joint onto shaft until circlip engages

Greasing => Table, Page
40-25

Special tools and workshop equipment required

VW416 B Tubular section
VW 412 Press tool
VW 426 Tubularsection
3110 Tubularsection
Kukko12/1 Puller
2050 Thrust pad

V.A.G 1275 Pliers
VW 161 A Circlip pliers
3207 Pressure spindle

Fig.1
Pressing off outer constant velocity joint

Clamp drive shaft with soft jaws in vice.
Detach large clamp and fold back boot.
Screw special tool into joint pin until constant velocity joint can be detached.

Fig.2
Installation position of spacer ring and dished washer (wheel end)

1 -
Dished washer
2 -
Spacer ring (plastic)

Fig.3
Venting rubber boot

Boot is often squashed on positioning it on housing. This produces a vacuum in the boot, which causes a fold to form whilst driving -arrow-.

Attention is therefore to be paid to the following:

Before tensioning clamps, lift boot to ensure pressure equalisation.

Fig.4
Tensioning large clamp for rubber boot

Fig.5
Tensioning large stainless-steel clamp for Hytrel boot

Apply pliers V. A.G 1682 as shown. Make sure jaws of pliers make contact with corners (arrows B) of hose clamp.
Tension hose clamp by turning spindle -A- with torque wrench (take care not to tilt pliers).

Notes:

Tightening torque: 20 Nm
Use torque wrench with 5...50 Nm adjustment range (e.g. V.A.G 1331).
Make sure thread of spindle on pliers moves freely. Lubricate with MoS2 grease if necessary.

If stiff, e.g. due to dirt on thread, required clamp tensioning force will not be attained with specified tightening torque.

Fig.6
Tensioning small clamp

Note:

This procedure applies to steel and stainless-steel clamps.