Volkswagen Golf Service & Repair Manual: Dismantling and assembling drive shaft

Volkswagen Golf Service & Repair Manual / Running gear, axles, steering / Rear suspension, drive shaft / Drive shaft / Dismantling and assembling drive shaft

Dismantling and assembling drive shaft

Special tools and workshop equipment required

Thrust plate -VW 401-

Thrust plate -VW 402-

Press tool -VW 408 A-

Press tool -VW 411-

Tube -VW 416 B-

Thrust washer -VW 447 H-

Dismantling and assembling drive shaft

Circlip pliers -VW 161 A-

Torque wrench -V.A.G 1331-

Torque wrench -V.A.G 1332-

Special pliers -V.A.G 1682-

Assembly tool -T10065-

Dismantling

Driving off outer constant velocity joint

–	Clamp drive shaft in vice using protective jaw covers.

–	Remove clamps.

–	Fold back boot.

–	Drive constant velocity joint off drive shaft using drift -A-.

Drift must be positioned exactly on ball hub of constant velocity joint.

Driving joint on

Dismantling and assembling drive shaft

Installation position of dished spring at outer joint

1 -	Dished spring

–	Insert new circlip.

–	Use plastic-headed hammer to drive joint onto shaft until circlip engages.

Dismantling and assembling drive shaft

Driving off cover for inner joint

Dismantling and assembling drive shaft

Pressing off inner constant velocity joint

–	Press off protective boot off joint using a drift.

–	Remove retaining ring.

–	Remove both clamps and slide boot towards outer joint.

Assembling

Dismantling and assembling drive shaft

Installation position of dished spring at inner joint

1 -	Dished spring

Dismantling and assembling drive shaft

Pressing on inner constant velocity joint

Note

Chamfer on internal circumference of ball hub (splines) must face contact shoulder on drive shaft.

–	Press joint on to stop.

–	Install retaining ring.

Dismantling and assembling drive shaft

–	Using bolts -arrows-, align new cover in relation to bolt holes.

The alignment must be very accurate, because no further alignment is possible once the part has been hammered on.

–	Drive on cover using a plastic hammer.

Dismantling and assembling drive shaft

Tighten clamp on outer joint

–	Position clamp tensioner -V.A.G 1682- as shown in diagram. Ensure jaws of tensioner lie in corners -arrows B- of ear on O-type clip.

–	Tighten clamp by turning spindle with a torque wrench (do not cant pliers).

Note

Due to the hard material of the protective boot (compared to rubber) and the necessity of using a stainless steel clamp, it is only possible to tension the clamp with clamp tensioner -V.A.G 1682-.

Specified torque: 25 Nm.

Use torque wrench -C - with setting range of 5 ... 50 Nm (e.g. torque -V.A.G 1331-).

Make sure thread of spindle -A- on pliers moves freely. Lubricate with MoS2 grease if necessary.

If the thread is tight (e.g. due to dirt), the required clamping force for the clamp will not be attained although the specified tightening torque is applied.

Dismantling and assembling drive shaft

Tightening clamp on small diameter

Dismantling and assembling drive shaft

Removing and installing drive shaft

Special tools and workshop equipment required Torque wrench -V.A.G 1332- ...

Loosening and tightening threaded connections of drive shaft

Special tools and workshop equipment required Socket, 24 mm -T10361A- ...

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