Repairing drive shafts — VW

Removing and installing drive shafts => page
40-2

Constant velocity joint, inner
Pressing off=> Fig.
15
Pressing on =>Fig.
17
Dismantling, checking and assembling =>Figs.
18
-
23
See note on lubrication.

Joint with centralising shoulder for gearbox 084

As of Chassis No. 172 BW 391 296 - 22. January 1981 only joint with centralising shoulder, flanged shafts and old/new gearbox as spare part.

Joint boot
Check for splits and wear

Shaft
Length varies according to gearbox =>Fig.
1

Turned shaft

As of 2.80 => page
40-62

Clip
Renew =>Fig.
6

Joint boot
Check for splits and wear

Dished washer
Installing =>Fig.
3

Distance washer
Installing =>Fig.
3

Constant velocity joint, outer
Removing =>Fig.
2
Dismantling =>Figs.
7
-
11
Installing: drive onto the shaft until the circlip engages in the shaft groove. See note on lubrication.
Golf/Scirocco with 81 kW engine differs => Fig.
12

Modification to circlip

As of Chassis No. 16 A 0 000 001 (Jetta)

17 A 0 089 772 (Golf)

53 A 0 000 001 (Scirocco) => page
40-48

Circlip
Renew
Install in the ball hub of joint

Hose clip
Renew => Fig.
6

Modification to constant velocity joint, outer

As of Chassis No. 15 EK 006 507

53 EK 012 218 => page
40-65

Note:

=>page
40-65

Pushing the vehicle when drive shafts are removed

=> page
40-67

Note:

Press 90 g MoS2 grease into outer constant velocity joint. When renewing the joint boot, add grease if required.
Lubricating inner joint press 45 g. MoS2grease into each side of joint (total 90 grams). When renewing the joint boot, add grease if required.

Protective cap
Drive off constant velocity joint => Fig.
14

Modification to dished washer

As of 2.80 => page
40-62

Dished washer
Installing =>Fig.
16

Circlip
Renew, removing and installing =>Fig.
13

Fig.1
Length of shafts

Model · Gearbox · Length "a" · Remarks
left · right
Golf and · Manual 020 · 445.5 mm · 658 mm · Left: solid
Scirocco · Manual 084 · 467.5 mm · 658 mm · Right: Tubular
Automatic 010 · 445.5 mm · 658 mm

Fig.2
Removing outer constant velocity joint

Open out the circlip (arrow A), and at the same time tap the end of joint (arrow B).
Pull joint off shaft.

Modification to circlip

From Chassis No.:

16 A 0 000 001 (Jetta)
17 A 0 089 772 (Golf)
53 A 0 000 001 (Scirocco)

An optional drive shaft which has the circlip for the outer constant velocity joint on the shaft is being installed.

The groove in the shaft has been moved accordingly. The former groove in the ball hub has been discontinued. Parts of new and old type cannot be combined.

Fig.3
Positions of dished washer and distance washer, formerly

1 -
Circlip
2 -
Distance washer
3 -
Dished washer

Circlip in hub

Fig.4
Positions of dished washer and distance washer, new

1 -
Circlip
2 -
Distance washer
3 -
Dished washer

Circlip on shaft

Fig.5
To remove constant velocity joint

Knock it off shaft by striking smartly with a light metal hammer.

To install constant velocity joint

Place circlip in groove and then knock joint on with the hammer.

Fig.6
Tighten hose clips