Dismantling and assembling drive shaft — VW

🧭 Before you start

Clamp the shaft in soft jaws, fold back the outer boot and pull the outer joint with the puller set. Fit a new retaining ring and boot, drive the joint on until the circlip engages and tension both clamps. For the inner joint, release the clamps, pull off the joint body, remove the circlip and pull off the roller star. Clean everything, fit the small clip and boot, drive the star on chamfer-first, fit the circlip, pack the grease from the repair kit in two halves and fit the boot and new clamps.

Fits: platform codes 121, BL1

• Special tools named: puller, torque wrench

Don't miss

• Always fit a new retaining ring on the outer joint.
• The chamfer on the triple roller star must face towards the drive shaft.
• Tension the stainless clamps with the clamp tensioner to 25 Nm; ordinary pliers will not do.
• Check the tensioner spindle thread runs freely, or the clamp will be under-tensioned at the correct torque.
• Split the repair kit grease: half into the joint, half behind it.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Clamp drive shaft in vice using protective jaw covers.
2. Open hose clip.
3. Fold back boot.
4. Set puller T10382 up so that smooth side of puller plate T10382/1 points to spindles T10382/2.
5. Assemble puller T10382 complete with multi-purpose toolVW 771.

6. Pull constant velocity joint from drive shaft with puller T10382 and multi-purpose toolVW 771.
7. Install new retaining ring.
8. If necessary, push new joint boot onto drive shaft.
9. Drive constant velocity joint onto shaft using plastic hammer until circlip engages.
10. Position clamp tensionerV.A.G 1682 as shown in diagram. Ensure jaws of tensioner lie in corners (arrows B) of clamp.
11. Tighten clamp by turning spindle with a torque wrench (do not cant pliers). [Note: Due to the hard material of the protective boot (compared to rubber) and the necessity of using a stainless steel clamp, it is only possible to tension the clamp with clamp tensionerV.A.G 1682.Specified torque: 25 Nm.Use torque wrench (C) with setting range of 5 ... 50 Nm (e.g. torqueV.A.G 1331).Make sure thread of spindle (A) on pliers moves freely. Lubricate with Mo S2 grease if necessary.If the thread is tight (e.g. due to dirt), the required clamping force for the clamp will not be attained although the specified tightening torque is applied.]
12. Position clamp tensionerV.A.G 1682 as shown in diagram. Ensure jaws of tensioner lie in corners (arrows B) of clamp.
13. Tighten clamp by turning spindle with a torque wrench (do not cant pliers). [Note: Due to the hard material of the protective boot (compared to rubber) and the necessity of using a stainless steel clamp, it is only possible to tension the clamp with clamp tensionerV.A.G 1682.Specified torque: 25 Nm.Use torque wrench (C) with setting range of 5 ... 50 Nm (e.g. torqueV.A.G 1331).Make sure thread of spindle (A) on pliers moves freely. Lubricate with Mo S2 grease if necessary.If the thread is tight (e.g. due to dirt), the required clamping force for the clamp will not be attained although the specified tightening torque is applied.] [Note: The lugs of deflector ring (1) must face towards outer joint.Deflector ring (1) must lie on contact surface of outer joint (arrow).] [Note: If deflector ring (1) is not positioned correctly or if it fell off outer joint, it must be driven onto outer joint to stop using thrust piece T10049.]
14. Unfasten both clamps on inner joint and push back boot.
15. Pull joint body off drive shaft.
16. Remove circlip (1).
17. Pull triple roller star (1) off drive shaft using a three arm puller, e.g. Kukko 45-1(2).
18. Pull boot off shaft.
19. Clean shaft, joint body and groove for seal.
20. Push small hose clip for boot onto shaft.
21. Push joint boot onto shaft.
22. Fit triple roller star (1) onto drive shaft (2). [Note: Ensure that chamfer (arrow) of triple roller star (1) faces towards drive shaft (2).]
23. Drive triple roller star (1) onto drive shaft using thrust piece T10421(2).
24. Insert circlip (1), ensuring that it is seated correctly.
25. Press half the drive shaft grease from the repair kit into the triple roller joint.
26. Slide joint body over rollers and hold.
27. Press the other half of the drive shaft grease from the repair kit into the back of the triple roller joint.
28. Install joint boot.
29. Tighten clamp on small diameter .
30. Tighten new clamp on constant velocity joint .

🎬 Related video tutorial

Independent AUTODOC tutorial for the same job, filmed on a different model (CADDY 3 Van) — the technique carries over, the fasteners and figures on this page are the ones for your car.

How to change cv joint on VW CADDY 3 Van

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