Removing and installing rear-axle shafts — VW

Special tools and workshop equipment required

VW 307a Retainer
Kukko 70/2 with 722 hooks

VW 240a

Fig.1
Support gearbox with assembly appliance

A -
VW 307a

Fig.2
Pull radial bearing off

A -
Internal puller
e.g. Kukko 70/2 with hooks 722

Fig.3
Unscrew bearing cap and remove axle tube with protective bellows completely

Fig.4
Take retaining ring (arrow) off with commercially available long nose pliers

Fig.5
Renew protective bellows

If the axle tube has been removed, use an original protective sleeve (single unit) if possible.

In axle tubes with mounting for the compensating spring the single unit protective bellows can be installed only from the spherical cap side. To do this trim spherical cap (arrow).

Turn protective bellows and fit side with bigger opening to the spherical cap first. Fit sleeve side with smaller opening with two screwdrivers. Move protective bellows to the bearing cap and turn to rear.

Fig.6
Press taper roller bearing in

Installation position: the open side of the plastic cage must face outwards.

A -
VW 240a

Fig. 7
Installation position of wheel bearing

1 -
Slide spacer, exterior
2 -
O-ring, big
3 -
O-ring, small
4 -
Radial bearing.
5 -
Slide spacer, exterior
6 -
Axle shaft.
7 -
Cover washer
8 -
Bearing flange
9 -
Washer, oil deflector
10 -
Castle nut
11 -
Brake drum
12 -
Bearing cap for rear wheel

Fig.8
Install bearing cap for rear wheel with oiled lug (arrow) facing downwards

Fig.9
Fit hose clip with commercially available pliers

The contact surfaces of the protective bellows on the axle tube cover and the axle tube itself must be free of oil and grease.
Fit hose clip after installing the gearbox to the axle tube side (arrow) to avoid damages to the protective bellows.

Fig.10
Check axle shaft for imbalance

Max permissible tolerance: 0.05 mm

If the axle shaft has light imbalances straight it in the straightening press when it is cold.

Fig.11
Adjust axle shaft

When using a feeler gauge the mounting play between the axle shaft wings (measured at the ball surfaces of the small side) and the inner diameter of the big drive pinion must be from 0.03 to 0.1 mm

The axle shafts and the big drive pinions are paired according to the tolerance respectively and divided into five groups.

Colour identification · Inner diameter of big drive pinion · Outside diameter of axle shaft
Yellow · 59.93-59.96 · 59.87-59.90
blue · 59.97-60.00 · 59.91-59.94
pink · 60.01-60.04 · 59.95-59.97
green · 60.05-60.07 · 59.98-60.00
White · 60.08-60.10 · 60.01-60.04

Drive pinions are supplied as spare parts with blue and pink colour identification and axle shafts with yellow, blue and pink identification. Colour identification fitting: in the recess of the pinion plane face (colour specks) and the axle shaft with 150 mm projection to the wing front side (circular).

Fig.12
Adjust axle shaft

Check play (0.1 - 0.3 mm) between the rear axle, the both sliding pieces and the big drive pinion with a feeler gauge. The play must be from 0.15 mm to 0.20 mm. If the play is too big (more than 0.30 mm) sliding pieces with oversize must be installed (with longitudinal slots) or the worn components must be renewed.

A too big play can lead to driving noises on the rear axle. If the play is too small the axle shaft wings may pit the sliding pieces. Lubricate components with grease MoS2 (Molybdenum disulphide).
Fig.13
Adjust axle shaft

Check mounting play "a" between retaining collar for the big drive pinions and the press rings when locking ring is installed. When using a feeler gauge the play must be 0.05 up to 0.2 mm.

The following press disks are available for the adjustment:

ET-No. (Part Number). · Thickness (mm)
113 517 167 E · 3.9
113 517 167 C · 4.0
113 517 167 D · 4.1
113 517 167 H · 4.2

Note:

Only the calibration to dimension "a" ensures the prescribed face clearance between the small and big drive pinions.

Fig.14
Adjust axle shaft

1 -
Adjustment cap
2 -
Axle tube cover
3 -
Shim
4 -
Bearing cap gasket
5 -
Axle tube spherical cap
6 -
Plastic cap

Install axle shaft free of play, if possible, together with the correct adjustment washers under the bearing cap for axle tube. The adjustment is right when the axle tube can be moved in all directions without catching or sticking.

Under no circumstances the play must exceed 0.2 mm. Before final assembly fit sealing ring and grease axle tube spherical cap on the inner and outer side with grease MoS2.

When installing, the adjusting washers must be inserted in the axle tube cover first and the sealing ring fitted continuously. Always keep this work sequence otherwise adjusting washer canting may cause leakage.