Repairing drive shaft with inner tripod joint — VW

The following description deals with the Audi TT 1999 ä. Therefore differences must be considered, if necessary.

Special tools and workshop equipment required

V.A.G 1682 Pliers
3340 Pliers
VW 402 Thrust plate
VW 411 Press tool
VW 412 Press tool
VW 416b Tube

VW 522 Support sleeve

V.A.G 1332 Torque wrench
Measuring range: 5...50 Nm.

Grease quantity and type

Outer joints are packed with grease G 000 603:

Inner tripod joints are packed with grease G 000 605:

Grease · of which in:
Outer joint · Total quantity · Joint · Boot
ø mm · [g] · [g] · [g]
88 · 100 · 50 · 50
98 · 120 · 80 · 40
Inner tripod joint
ø mm
72 · 110 · 70 · 40

Regrease joint, if necessary, when replacing the boot.

Outer constant velocity joint
Replace only as complete unit
Removing => Fig.
1
Installing => Page
40-115
Fig.
4
Greasing => Page
40-127
Checking => Page
40-119

Hexagon bolt
Renew each time after removing

Tightening torque => Page
40-55
Observe notes on assembly when fitting => Page
40-55
Observe notes on assembly when removing => Page
40-55

Outer constant velocity joint
Replace only as complete unit
Removing => Fig.
1
Installing: Strike shaft with plastic hammer until installed circlip is disengaged
Greasing => Page
40-127
Checking => Page
40-119

Tighten self-locking 12-point nut
Profiled shaft
Tripod joint boot
Hose clip
Multi-point socket-head bolt
Pretensioning torque: 10 Nm
Tightening torque: 70 Nm

Joint

Tripod star
The chamfer -arrow- faces splines of drive shaft

Rollers are not removable

Circlip
Replace
Insert in shaft groove

O-ring
Replace

Cap
Replace

Hose clip
Always replace
Tensioning => Fig.
4

CV joint boot
Check for cracks and abrasion
Material: Hytrel (polyelastomer)

Hose clip
Always replace
Tensioning => Fig.
3

Dished washer
Installation position => Fig.
5

Spacer (plastic)
Installation position => Fig.
5

Circlip
Always replace
Insert in shaft groove

Fig.1
Removing outer constant velocity joint

Knock off drive shaft by hitting hard with a light-alloy hammer.

Fig.2
Venting bellows

The CV joint boot is often squashed when installing it on the housing. This creates a vacuum inside the bellows which causes inward folding (arrow) whilst driving. Therefore, briefly vent the bellows at the small diameter end after fitting to equalise pressure.

Fig.3
Hose clamps on outer joint

Apply pliers V.A.G 1682 as shown. Thereby ensure that the jaws of the pliers fit into the corners (arrows B) of the hose clamp.
Tension hose clip by turning screw with a torque wrench (take care to keep pliers straight).

Notes:

On account of the hard material (as opposed to rubber) of the CV joint boot and the stainless steel hose clip thus required, hose clip can only be tensioned using pliers V.A.G 1682.
Tightening torque: 25 Nm
Use torque wrench with 5...50 Nm adjustment range (e.g. V.A.G 1331).

Ensure that the spindle thread of the pliers moves freely. If necessary, lubricate with MoS2 grease.
Stiffness, e.g. through dirty thread, prevents required tensioning force of hose clip being reached with specified tightening torque.

Fig.4
Tensioning hose clamp at small diameter

Fig.5
Fitting location of spacer ring and dished washer

1 -
Dished washer
2 -
Spacer ring (plastic)