Repairing drive shaft — VW

VW
Golf
1984
Jetta
1984
Running gear
Running gear
Edition
11.2005
Repairing drive shaft
Note
Grease filling
high-temperature grease
G 052 133 A2
: Outer CV joint: 90 g, inner CV joint: 120 g
Greasing outer joint: press half of the grease into the joint and the other half evenly into the bellows.
Greasing inner joint: Press half of the grease into the joint from both sides, the other half evenly into the bellows.
Regrease joint if required when renewing boot.
Retaining ring
Renew.
Expand and compress with
circlip pliers
VW 161 A
.
Gasket
Renewing. Pull off protective foil and stick into joint.
Only on 100 mm ∅ constant velocity joints.
Inner constant velocity joint ∅ 100 mm
For vehicles with output of 66 kW and above.
Different material for 16V vehicles.
Renew only complete.
Pressing off
Fig.
.
Pressing on
Fig.
.
Greasing
Chapter
Checking
Chapter
As of 08.89 also for vehicles over 62 kW.
Inner constant velocity joint ∅ 94 mm
For vehicles with output up to 65 kW.
Renew only complete.
Pressing off
Fig.
.
Pressing on
Fig.
.
Greasing
Chapter
Checking
Chapter
Dished spring
Toothed in inner ∅
Installation position: larger ∅ (concave side) contacts constant velocity joint.
CV joint boot for 100 mm ∅ CV joint
With vent hole
Check for splits and chafing.
Installation position for left shaft
Fig.
Installation position for right shaft
Fig.
.
Coat cap sealing surface with
sealant
D 454 300 A2
.
Drive off with drift.
CV joint boot for 94 mm ∅ CV joint
Check for splits and chafing.
Drive off with drift.
Clamp
Renew.
Tensioning
Fig.
and
Fig.
.
Hose clip
Renew, separate closed metal rings with metal saw.
Tensioning
Fig.
and
Fig.
.
Modified as of 01.90
Fig.
.
CV joint boot for 90 mm ∅ CV joint
Check for splits and chafing.
Allow air to enter joint protective boot briefly to balance pressure before tightening small clamp in place
Fig.
.
CV joint boot for 81 mm ∅ CV joint
Check for splits and chafing.
Allow air to enter joint protective boot briefly to balance pressure before tightening small clamp in place
Fig.
.
Modified as of 01.90
Fig.
.
Outer constant velocity joint ∅ 90 mm
For vehicles with output of 66 kW and above.
Different material for 16V vehicles.
Modification: As of 08.87 contact shoulder for wheel bearing modified
Fig.
.
Renew only complete.
Removing
Fig.
Installing: drive onto shaft with plastic hammer until compressed circlip seats
Greasing
Chapter
Checking
Chapter
Outer constant velocity joint ∅ 81 mm
For vehicles with output up to 65 kW.
Modification: As of 08.87 contact shoulder for wheel bearing modified
Fig.
.
Renew only complete.
Removing
Fig.
Installing: drive onto shaft with plastic hammer until compressed circlip seats
Greasing
Chapter
Checking
Chapter
Retaining ring
Renew.
Insert in groove in shaft.
Thrust washer
Dished spring
Outer ∅ (concave side) contacts thrust washer.
Drive shaft for vehicles with output of 66 kW and above
Constant velocity joint splines 4 mm longer than shafts for lower-output engines, measured from dished spring support to retaining ring groove.
Length of shaft
Fig.
.
As of 08.89 also installed in vehicles over 62 kW.
Drive shaft for vehicles with output up to 65 kW
Length of shaft
Fig.
.
As of 08.89 also installed in vehicles up to 59 kW.
Damper weight (two-piece)
Installed on right shaft in vehicles with 51 kW engines and vehicles with diesel engine.
Removing and installing
Fig.
Installation position
Fig.
.
Damper weight (one-piece)
Installed as of 04.88 (standard).
Use damper weight
Item
as spare part.
Installation position
Fig.
.
Removing and installing right drive shaft damper weight
The damper consists of two halves. Both halves are joined to one another by spring pins
arrow
.
Installation position
Fig.
.
Note
Before driving in spring pin, protect shaft paint finish against damage.
Adhesive tape is applied on inner diameter to prevent axial movement. Before re-installing damper weight, check adhesive effect of adhesive tape. If necessary, renew adhesive tape or apply another adhesive.
Installation position of damper weight
(In drive shafts with CV joint boot without vent bore)
When installing damper weight
A
, prescribed installation position must be ensured. Adherence to dimension a = 4 mm, measured from conical part of shaft to damper weight, is necessary to do this.
Installation position of damper weight
(In drive shafts with ventilated CV joint boot)
When installing damper weight
A
, prescribed installation position must be ensured. Dimension a = 478 mm must be adhered to.
Note
If damper weight is damaged, replace with two-piece damper weight.
CV joint with modified contact shoulder
As of 08.87
Dimension a = ∅ 53 mm
Up to 08.87
Dimension a = ∅ 50 mm
Previous drive shaft/outer CV joint version (small contact shoulder) must not be installed in vehicles as of model year 1988, as the CV joint-wheel bearing contact area is then too small.
Previous drive shaft/outer CV joint version will be discontinued when consumed.
Removing outer joint
Drive joint off drive shaft with a firm blow from an aluminium hammer.
Pressing off inner joint
Support ball hub when performing this step.
Pressing on inner joint
Press on joint to stop. Insert retaining ring.
Note
Chamfer on the inner circumference of ball hub (splines) must face the contact shoulder of the drive shaft.
Installing CV joint boot on left drive shaft
Vehicles with output of 66 kW and more: Before installing CV joint boot on drive shaft, mark dimension a = 17 mm with e.g. paint or adhesive tape. Under no circumstances should paint finish be damaged with a sharp tool.
Installing CV joint boot on right drive shaft
Vehicles with output of 66 kW and above. The large diameter of vent chamber
A
must fit on the larger diameter.
B
= vent bore
Venting joint boot
The boot is frequently pressed in when installed on the joint body. This creates a partial vacuum inside the boot which draws in a fold
arrow
when the car is driven. Therefore, after fitting boot, lift boot at small diameter end to equalise pressure.
Tension hose clip or clamp with
hose clip pliers
V.A.G 1275
.
Modified CV joint boot and hose clip
Apply
clamp tensioner
V.A.G 1682
as shown in figure. Ensure jaws of tensioner contact corners
arrows B
of hose clamp.
Tighten hose clip by turning spindle
A
with torque wrench (take care to keep clamp tensioner straight).
Note
Hose clip can only be tensioned with
clamp tensioner
V.A.G 1682
.
Tightening torque: 25 Nm.
Use torque wrench with setting range of 5…50 Nm (e.g.
V.A.G 1331
).
Ensure that thread of tensioner spindle moves freely. If necessary lubricate with MoS
2
grease.
If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clip with the specified tightening torque.
Tensioning hose clip at small diameter of boot is carried out in the same way.
Length of shaft
Gearbox version
Length dimension
a
(mm)
Remarks
Left
Right
Manual gearbox 020
Note
and 02A
443
677.2
Left full shaft
right tubular shaft
Manual gearbox 084 and 085
465
677.2
Left full shaft
right tubular shaft
Automatic gearbox
443
677.2
Left full shaft
right tubular shaft
Golf syncro manual gearbox 009 and 02C front axle, rear axle
443
543.6
513.5
404.5
Left/right full shaft
left/right full shaft
Drive shafts for GTI/GLI vehicles have 4 mm longer splines from contact shoulder for dished spring to groove for circlip.