Disassembly of the half shaft
1. Safety washer; 2. Gasket; 3. Internal swivel synchronizer; 4. Clamp; 5. Protective cover of the swivel synchronizer. Check for scuffs and cuts!; 6. Half shaft 7. Clamp; 8. Belleville spring; 9. Slip ring; 10. Safety washer; 11. Protective cover of the external swivel synchronizer; 12. Sleeve clip; 13. External swivel synchronizer
Disassembly
1. Remove half shaft.
2. Cut with pliers on both sides of the protective cover of the hinge, sleeve clamps and remove. Slide the cover back.
3. Press out the outer hinge. To do this, place the axle shaft in a vise with protected jaws and clamp. Turn the cover in the opposite direction. Screw in the tool KAG-3207 with the M16 threaded part until the synchronizer joint is pressed out of the profile shaft.
4. Inner joint: press and remove the safety ring with suitable round-nose pliers (1) - see fig. Half shaft disassembly.
5. Press out the inner joint with a suitable press, while resting against the ball hub.
6. Inner hinge: remove gasket (2) - see fig. Half shaft disassembly.
Assembly
1. Replace brittle or defective axle shaft boots.
2. Put protective covers with sleeve clamps on the shaft.
3. Slide the disc spring onto the profile shaft (8) and sliding ring (9). Set the cup spring correctly (see fig. Disassembly of the half shaft). Large diameter belleville spring (concave side) rests against the sliding ring.
4. Install a new safety washer in the shaft groove.
5. Lubricate the outer joint with 120 g of VWG-6.3 grease. At the same time, press about 80 g of grease through the internal splines of the ball hub into the outer joint. Apply about 40 g of grease to the inside of the hinge.
Attention! If only the joint protector is to be replaced, re-lubricate if necessary.
6. Press the outer joint onto the shaft with a plastic hammer until it is locked by the safety washer.
7. Put on the protective cover of the hinge and set the sleeve clamp on the larger diameter with suitable pliers.
Attention! Often, when putting on a protective cover on the hinge body, it is pressed in. As a result, a vacuum is formed above the boot, which draws the lubricant in during operation. Therefore, after installation, using a screwdriver, on the side of the smaller diameter, it is necessary to slightly lift the cover and equalize the pressure.
8. Slide the sleeve clamp onto the smaller diameter.
9. Inner joint: Press in 120 g of VWG-6.3 grease on each side of the joint. If only the joint protector is to be replaced, add lubricant if necessary.
10. Press in the inner joint with a suitable press until it stops.
11. Install a new lock washer into the groove of the shaft with the help of expanding round-nose pliers.
12. Internal hinge: fasten the protective cover with a sleeve clamp and attach a new gasket to the hinge, having previously removed the protective chamfer from it.
13. Install half shaft.
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