Repairing constant velocity joint — VW

Repairing constant velocity joint
Removing constant velocity joint:
Note
The flexible couplings have alignment marks which mark the position of imbalance.
Before pulling off joint, transfer exact position of imbalance marks to shaft.
When reconnecting, align marks to prevent imbalance.
Clamp propshaft in vice with jaw protectors.
Prise out cap with a screwdriver.
Remove seal
arrow
.
Drive down joint protective boot with a brass or copper drift.
Note
Clamp must not be loosened.
Remove retaining ring using
pliers
3340
.
Position component and tools as illustrated.
Press off constant velocity joint.
Open small clamp on propshaft and pull protective boot off propshaft.
Installing constant velocity joint
Apply
sealant
Electronic Parts Catalogue
to cleaned inner surface of cap of joint boot. Apply sealant bead of 2-3 mm in diameter without interruption along inside of holes
arrows
.
Push joint protective boot with small clamp onto propshaft.
Propshaft, protective boot and contact surface of cap must be free of grease!
Drive on joint to stop using
drift sleeve
VW 244 B
.
Chamfer on inner circumference of ball hub (splines) must face contact shoulder of propshaft.
Insert new retaining ring.
Check retaining ring is seated correctly.
Before installing cap, press 40 grams of
joint grease
Electronic Parts Catalogue
into joint protective boot through ball race.
Note
Sealant bead must not be damaged when installing.
Align cover with bolts
arrows
with bolt holes.
Alignment must be very precise because it is not possible to repeat alignment after driving on.
Drive on cover with a plastic hammer.
Remove sealant which is pressed out.
Press 20 grams of
joint grease
Electronic Parts Catalogue
into joint protective boot through ball race.
Clean contact surface for seal.
Pull off protective film and bond seal
arrow
in constant velocity joint.
Align new cover
A
with bolt holes.
Alignment must be very precise because it is not possible to repeat alignment after pressing on.
Press on cover
A
as shown.
A piece of flat steel, for example, can be used in place of
retainer
2036/1
.
Position joint protective boot in outer groove
arrow 2
. Inner groove
arrow 1
must remain visible.
Attach clamp and tighten:
Close clamp with
pliers
3340
.
The
pliers
3340
must be applied to front of clamp as shown in figure.