Contents: Disassembly ↓ Assembly ↓
Damaged bellows must be replaced immediately. To replace bellows, the cardan shaft must be disassembled. A defective ball joint is determined by knocks and clicks when turning the car.
Note: When the cardan shaft is removed, the vehicle should not rest on the wheels with its entire weight, since the lack of axial compression will damage the hub bearing. If necessary, install the outer joint tailpiece instead of the cardan shaft and tighten the fastening to a torque of 50 Nm.
Disassembly
Remove the propeller shaft, see the relevant chapter.
Use nippers to cut the fastening clamps of the corrugated covers on both hinges and remove them. Move the corrugated covers onto the shaft.
Clamp the cardan shaft in a vice with aluminum protective jaws.
External constant velocity joint: knock the joint off the shaft with strong blows from a plastic hammer.
Remove the retaining ring "16" from the joint, see figure S40-0255.
Inner constant velocity joint: Use a suitable rod to knock the protective cap off the joint.
Inner constant velocity joint: remove the retaining ring with suitable pliers, e.g. VAG-161a or HAZET 2525K.
The original text can be found at: vwmanual.ru
Remove the inner joint using a suitable press, supporting the inner hub of the joint. Remove the corrugated cover, disc spring, and joint sealing gasket from the shaft.
Assembly
Replace fragile or defective corrugated covers.
Place the corrugated cover with a clamp for the inner joint on the shaft.
Inner and outer joints: fill the new joint with high-temperature grease, such as VW Group G 000 603. For a new joint, place half the amount of grease in the bellows and press the other half into the joint. If only the bellows is being replaced, only top up the joint with grease if necessary.
Inner constant velocity joint: place the disc spring "1" on the cardan shaft. The disc spring must be installed correctly: its large diameter rests on the joint.
Using a suitable press, press the inner hinge until it stops.
Note: The chamfer on the inner diameter of the joint hub (at the splines) must face the support flange of the cardan shaft. Install a new retaining ring into the annular groove of the shaft using suitable pliers, such as VW-161a or HAZET 2525K.
Place the corrugated cover for the outer hinge on the shaft together with the clamp.
Install the corrugated covers in the installation position.
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.
To tighten the clamps (made of alloy steel)it is necessary to use special pliers, for example, HAZET 1847, otherwise the required tightening force will not be achieved. Place the pliers, as shown in the figure, with the teeth against the corners of the clamp "arrows B". In this position, tighten bolt "A" to tighten the clamp with a torque wrench to 20 Nm. Tightening the clamp on a small diameter corrugated cover is performed in a similar way.
Note: The thread of the pliers must move easily and, if necessary, should be pre-treated with MoS₂ lubricant.
Inner constant velocity joint: glue a new sealing gasket to the joint, having first removed the protective film from it.
Install the cardan shaft, see the relevant chapter.
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