Repairing three-part propshaft — VW

Repairing three-part propshaft
Special tools and workshop equipment required
Drift sleeve
VW 244 B
Drive shaft fitting appliance
VW 391
Pressure plate
VW 401
Pressure plate
VW 402
Press tool
VW 407
Press tool
VW 408 A
Support sleeve
VW 522
Tensioner
40-204 A
Hose clip pliers
V.A.G 1275
2
Puller
Kukko 18/0
3
Splitter
Kukko 17/1
Note
If one of the three propshaft tubes is damaged, the entire propshaft need not be renewed. The respective propshaft tube can be renewed together with constant velocity joints or flanges.
The centre and rear propshaft tubes can only be renewed together. Otherwise rumbling and droning noises may result.
The propshaft tubes and the above-named parts are balanced together. They cannot be balanced with workshop equipment. Therefore, an individual propshaft tube can be renewed only together with the above-named parts.
Keep propshaft straight; only store and transport fully extended.
Before dismantling, mark positions of all parts in relation to each other. Assemble in same position; otherwise an imbalance may be created which causes damage to bearing and rumbling noises.
Flexible coupling with heat shield
Installation position
Fig.
.
12-point collar bolt, 55 Nm
Bolt length 30 mm.
Note
Do not use hexagon-head bolts.
Front propshaft tube
Do not damage centring sleeve or seal inside flange when removing and installing
Chapter
.
Mark installation position relative to centre propshaft
Item
.
Can be renewed together with parts
Item
through
Item
.
Before removing flexible joint
Item
and constant velocity joint
Item
, mark positions of parts relative to propshaft tube and if appropriate, transfer balancing marks
Fig.
.
Attachment to flexible joint
Fig.
.
Attachment to centre propshaft tube
Fig.
.
Socket head bolt, 30 Nm
Lock plate
Clamp
Tensioning
Fig.
.
Constant velocity joint boot
Drive off with a drift before pressing off constant velocity joint.
Check for damage.
Constant velocity joint
Before removing, transfer balancing mark to propshaft
Fig.
.
If present, drive sealing cap off constant velocity joint with a drift.
Pressing off
Fig.
.
Repairing
Running gear, axles, steering from January 1996
Rep. Gr.
40
Repairing drive shaft
.
Installation position: step along outer circumference faces centre propshaft.
Pressing on
Fig.
.
If present, drive sealing cap off constant velocity joint with a drift. Renew cover if necessary.
Retaining ring
Renew.
Seal
Pull off protective foil.
Glue seal into joint.
Hexagon bolt, 60 Nm
Washer
Always renew.
Flange
Before removing, transfer balancing mark to propshaft
Fig.
.
Pulling off
Fig.
.
Pulling on
Fig.
.
Centre bearing
Pulling off
Fig.
.
Installation position
Fig.
.
Driving on
Fig.
.
Rubber disc
Installation position
Fig.
.
Centre propshaft tube
Mark installation position relative to front and rear propshafts.
Mark direction of travel.
Can be renewed together with parts
Item
through
Item
and
Item
.
Before removing flanges
Item
, mark positions of parts relative to each other and if appropriate, transfer balancing marks
Fig.
.
Identification of centre propshaft tubes
Fig.
.
Protective ring
Can be pulled off without removing parts
Item
through
Item
.
Rear propshaft tube
Do not damage centring sleeve and seal in centre of flange when removing and installing
Chapter
.
Mark installation position relative to centre propshaft
Item
.
Can be renewed together with parts
Item
through
Item
and
Item
.
Before removing constant velocity joint
Item
, mark position of parts relative to each other and if appropriate, transfer balancing marks
Fig.
.
Attachment to centre propshaft tube
Fig.
.
Flexible coupling with balance weight
Three of the projecting sleeves of the flexible coupling engage in mounting holes of the viscous coupling and three in propshaft.
Before removing, mark position of parts relative to each other.
When renewing rear propshaft tube or flexible coupling, balancing marks must be aligned.
12-point collar bolt, 55 Nm
Bolt length 42 mm.
Installation position of flexible coupling
Three projecting sleeves
A
each on gearbox flange and propshaft flange engage in mounting holes of flexible coupling.
Shield
arrow
faces towards gearbox.
Transfer balancing marks
A
from drive flange (fig.) or constant velocity joint to propshaft (marks
B
).
Note
Balancing marks
A
may be located on the inside of the drive flange.
Attaching front propshaft tube and rear propshaft tube to centre propshaft tube
The individual propshaft tubes bear balancing marks on the flanges or constant velocity joints
arrows
.
During installation, the balancing marks of the individual propshaft tubes must align.
Pressing off constant velocity joint
Pressing on constant velocity joint
Press on carefully.
Tighten
tensioner
40-204 A
securely. Propshaft must not be pushed down within tensioner, or paintwork will be damaged.
Repair possible paint damage as follows: remove residual grease or oil with
nitro thinner
L 001 600
. Apply
2 component acrylic paint
ALN 769 041
with
hardener
ALZ 009 001
.
Tightening clamp
Tightening clamp allocation in case of repair
Electronic parts catalogue
.
Pulling off flange
Pulling on flange
Pulling off centre bearing
A
Splitter, 12...75 mm, e.g.
Kukko 17/1
B
Puller, e.g.
Kukko 18/0
C
Collar bolt M8 x 20
Installation position of centre bearing
Smaller chamfer
arrows
faces centre propshaft tube.
Driving on intermediate bearing
Drive on intermediate bearing to stop.
Installation position of rubber disc
Dimension
a
= 10 mm
Identification of centre propshaft tubes
Dimension
a
Vehicles with long wheelbase
1,405.1 mm
Vehicles with short wheelbase
1,005.1 mm