Removing and installing outer constant velocity joint of drive shafts »VL100« and »VL107« — VW

Removing and installing outer constant velocity joint of drive shafts
»VL100«
and
»VL107«
Caution
When removing and installing drive shafts, do not allow them to hang free or stop against joints due to over bending.
Special tools and workshop equipment required
Thrust plate
VW 401
Thrust plate
VW 402
Press tool
VW 408 A
Press tool
VW 411
Tube
VW 416 B
Thrust washer
VW 447 H
Circlip pliers
VW 161 A
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Special pliers
V.A.G 1682
Assembly tool
T10065
Multi-purpose tool
VW 771
Puller
T10382
Locking pliers for Phaeton steering rack
VAS 6199
Removing
Removing drive shaft
Chapter
Clamp drive shaft in vice using protective jaw covers.
Open clamps on joint boot.
Push back joint boot.
Remove remains of grease using a clean cloth.
Set
puller
T10382
up so that smooth side of
puller plate
T10382/1
points to
spindle
T10382/2
.
Assemble
puller
T10382
complete with
multi-purpose tool
VW 771
.
Pull constant velocity joint from drive shaft with
multi-purpose tool
VW 771
and
multi-purpose tool
VW 771
.
1 =
Puller plate
T10382/1
2 =
Spindle
T10382/2
Installing
If necessary, press new joint boot onto drive shaft
Chapter
.
Note
Note installation position of dished spring and spacer ring on outer joint.
1 =
Dished spring
2 =
Thrust washer
Install new retaining ring.
Apply 60 g of
constant velocity joint grease
G 052 738 A2
to outer constant velocity joint through ball tracks.
Fill 60 g of
constant velocity joint grease
G 052 738 A2
into joint boot.
Drive clean and greased constant velocity joint onto shaft using plastic head hammer until circlip engages.
Note
Make sure that deflector ring
1
is clipped completely onto outer joint.
Deflector ring
1
must align with contact surface of outer joint
arrow
.
Tightening large clamp on outer constant velocity joint - Method 1:
Apply
clamp tensioner
V.A.G 1682
as shown in illustration. Ensure edges of tool lie in corners of ear
B
on clip.
Tighten clip by turning spindle
A
with the
torque wrench
V.A.G 1331
. Specified torque: 25 Nm.
Note
Due to the hard material of the joint boot and, consequently, to the use of a stainless steel clamp, it is possible to tension the clamps only with
clamp tensioner
V.A.G 1682
.
Make sure that thread of spindle
A
of
clamp tensioner
V.A.G 1682
moves easily. If necessary, lubricate the thread with MOS 2 grease.
If the thread is tight (e.g. due to dirt), the required clamping force for the clip will not be attained although the correct torque is applied.
The
clamp tensioner
V.A.G 1682
must not be twisted or canted as it is tightened.
Tightening large clamp on outer constant velocity joint - Method 2:
Insert lug
1
of clamp into guide
arrow
.
Compress clamp with pliers, e.g.
locking pliers for Phaeton steering rack
VAS 6199
until upper part
1
locks with guide
arrow
.
Tightening small clip on outer constant velocity joint:
Apply
clamp tensioner
V.A.G 1682
as shown in illustration. Ensure edges of tool lie in corners of ear
B
on clip.
Tighten clip by turning spindle
A
with a
torque wrench
V.A.G 1331
C
. Specified torque: 25 Nm.
Note
Due to the hard material of the joint boot and, consequently, to the use of a stainless steel clamp, it is possible to tension the clamps only with
clamp tensioner
V.A.G 1682
.
Make sure that thread of spindle
A
of
clamp tensioner
V.A.G 1682
moves easily. If necessary, lubricate the thread with MOS 2 grease.
If the thread is tight (e.g. due to dirt), the required clamping force for the clip will not be attained although the correct torque is applied.
The
clamp tensioner
V.A.G 1682
must not be twisted or canted as it is tightened.