General instructions
Replace defective corrugated boots immediately. To replace the boots, the cardan shaft must be disassembled. If dirt has penetrated the grease, wash the joint and fill it with new G6 grease. A defect in the joint balls is recognized by the impact change in load when switching to engine braking mode and by clicking noises. In this case, replace the joint as a set.
Attention: When the cardan shaft is removed, the vehicle must not be moved, since the lack of axial pressure will damage the hub bearing.
Disassembly
Remove the propeller shaft.
Cut the clamps on both hinges with nippers and remove. Move the hinge covers back.
Outer joint: Knock the joint off the drive shaft with strong blows from a light alloy hammer.
Inner joint: Knock the protective cap off the joint with a suitable rod.
Inner joint: remove the retaining ring with suitable pliers, e.g. VW-161 a or HAZET 2525K.
Remove the inner joint using a suitable press. Support the joint hub while doing so.
Remove the disc spring and corrugated boot from the drive shaft.
Inner joint: On vehicles with engines over 90 hp and all models with 10/93, remove the additional sealing gasket.
Assembly
Replace fragile or defective covers.
Place the cover with the clamp for the inner joint on the shaft.
Inner joint: place the disc spring on the cardan shaft. The disc spring must be installed correctly: its large diameter rests on the joint.
Inner joint: fill the new joint with 110 g of G6 grease. Distribute the grease equally between the joint and the bellows. If only the bellows is being replaced, only add grease to the joint.
The inner joint is pressed in until it stops using a suitable press.
Note: Chamfer on the inner diameter of the joint hub (toothed ring) must be facing the support flange of the cardan shaft.
Install a new retaining ring into the shaft groove using suitable pliers, such as VW-161a or HAZET 2525.
Vehicles with engines from 90 hp and all models from 10/93: indicate the installation dimension for the corrugated cover.
Before installing the corrugated cover on the cardan shaft, mark the installation position with paint or adhesive tape. Do not use: a scriber, and do not damage the protective varnish with any other sharp object.
Left propeller shaft: size a = 17mm
Right cardan shaft: The large diameter ventilation chamber "A" must be placed on the large diameter shaft pipe. B is the ventilation hole.
Inner joint: Lubricate the clean end of the joint boot cap with VAG-D3 repmetic. Put the cap on the joint body.
Place the corrugated outer joint boot onto the shaft together with the clamp and collar.
Outer hinge: fill the new hinge with 110 g of G6 grease. Spread the grease equally between the hinge and the bellows. If you are replacing only the bellows, only add grease to the hinge.
Place the disk spring "3" and the spacer washer "2" on the cardan shaft. In this case, the disk spring must be installed correctly: its large diameter rests on the spacer washer. The spherical surface of the spacer washer faces the hinge.
Insert a new retaining ring into the groove of the shaft. Drive the retaining ring onto the shaft with a rubber hammer until it locks into the groove.
The constant velocity cardan joint is placed on the shaft using blows from a plastic or light metal hammer.
Place the corrugated cover in the correct position and secure it with a clamp.
1.6 l petrol engine and turbocharged diesel engines: improved bellows are installed on the outer joints of the cardan shafts of vehicles with these engines from 1/90. Due to the more durable material of the bellows, new clamps made of alloy steel are also installed. These clamps can no longer be tightened with the previous VAG 1275 pliers. The pliers shown in the figure must be used. The cutting edges of the pliers must rest against the corners (arrows B) of the clamp. In this position, tighten bolt "A" with a torque wrench to 25 Nm and thus tighten the clamp. Tightening the clamp on the small diameter of the bellows is carried out in a similar manner.
Note: When installing the cover on the hinge body, it often gets compressed. As a result, a vacuum of air appears under the cover, which pulls the cover inward during operation. Therefore, after installing the cover, you need to slightly lift its edge on the small diameter side with a screwdriver to equalize the pressure.
Inner joint: On vehicles with engines over 90 hp and on all models with 10/93, glue a new sealing gasket into the joint, having first removed the protective film from it.
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