Dismantling and assembling drive shaft, Crafter 4MOTION with Achleitner four-wheel drive — VW

Dismantling and assembling drive shaft, Crafter 4MOTION with Achleitner four-wheel drive
Special tools and workshop equipment required
Thrust plate
VW 401
Thrust plate
VW 402
Press tool
VW 408 A
Support sleeve
VW 522
Tensioner
40 - 204 A
Special pliers
V.A.G 1682
Multi-purpose tool
VW 771
Puller
T10382
Torque wrench
V.A.G 1331
Removing outer constant velocity joint
Clamp drive shaft in vice using protective jaw covers.
Fold back boot.
Set
puller
T10382
up so that smooth side of
puller plate
T10382/1
points to
spindles
T10382/2
.
Assemble
puller
T10382
complete with
multi-purpose tool
VW 771
.
Pull constant velocity joint from drive shaft with
puller
T10382
and
multi-purpose tool
VW 771
.
Puller plate
T10382/1
Spindles
T10382/2
Driving on outer constant velocity joint:
Install new retaining ring.
If necessary, push new joint boot onto drive shaft.
Knock onto shaft with plastic hammer until circlip engages.
Driving off cover for inner joint
Remove retaining ring.
Remove both clamps and slide boot towards outer joint.
Drive off boot with drift.
Pressing off inner constant velocity joint
Assembling
Pressing on inner constant velocity joint
Press joint on to stop.
Install retaining ring.
Coat sealing surface of cover with
sealant
Electronic Parts Catalogue
.
Apply an unbroken bead of sealant of 2…3 mm in diameter onto clean surface of cover in area of inner holes
arrow
.
Using bolts
arrows
, align new cover in relation to bolt holes.
The alignment must be very accurate, because no further alignment is possible once the part has been hammered on.
Drive on cover using a plastic hammer.
Wipe off surplus sealant.
Tighten clamp on outer joint
Position
clamp tensioner
V.A.G 1682
as shown in diagram. Ensure jaws of tensioner lie in corners
arrows B
of ears on O-type clip.
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 tensioner
V.A.G 1682
.
Use torque wrench
C
with adjustment range 5 … 50 Nm, (e.g.
torque wrench
V.A.G 1331
).
Make sure thread of spindle
A
on pliers moves freely. Lubricate with MoS2 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.
Tightening clamp on small diameter
Specified torque
Component
Specified torque
Clamp
25 Nm