Contents: Disassembly ↓ Assembly ↓
Disassembling the axle shaft
1. Safety washer; 2. Gasket; 3. Internal articulated synchronizer; 4. Clamp; 5. Protective cover of the articulated synchronizer. Check for abrasions and cuts!; 6. Half shaft 7. Clamp; 8. Disc spring; 9. Sliding ring; 10. Safety washer; 11. Protective cover of the outer articulated synchronizer; 12. Sleeve clamp; 13. External articulated synchronizer
Disassembly
1. Remove the axle shaft.
2. Cut the sleeve clamps on both sides of the hinge protective cover with pliers and remove. Move the cover back.
3. Press out the outer joint. To do this, install the axle shaft in a vice with protected jaws and clamp it. Turn the cover in the opposite direction. Screw in the KAG-3207 device with the M16 threaded part until the synchronizer joint is pressed out of the profile shaft.
4. Inner joint: squeeze and remove the retaining ring (1) with suitable round-nose pliers – see Fig. Disassembling the axle shaft.
5. Press out the inner joint with a suitable press, while pushing against the ball hub.
The original can be viewed on the portal [VWmanual]
6. Inner joint: remove the gasket (2) – see Fig. Disassembling the axle shaft.
Assembly
1. Replace brittle or faulty axle shaft covers.
2. Place protective covers with sleeve clamps on the shaft.
3. Place the disc spring (8) and sliding ring (9) on the profile shaft. Install the disc spring correctly (see Fig. Disassembling the axle shaft). Large diameter disc spring (concave side) rests against the sliding ring.
4. Install a new safety washer into the shaft groove.
5. Lubricate the outer joint with 120 g of VWG-6.3 grease. Press about 80 g of grease through the inner splines of the ball hub into the outer joint. Apply about 40 g of grease to the inner side of the joint.
Attention! If only the hinge protective cover is to be replaced, add lubricant if necessary.
6. Using a plastic hammer, press the outer joint onto the shaft until it is secured by the safety washer.
7. Place the protective cover on the joint and install the sleeve clamp on the larger diameter using suitable pliers.
Attention! Often when putting on the protective cover on the hinge body, it is pressed. As a result, a vacuum is formed above the cover, which during operation draws the grease inside. Therefore, after installation, using a screwdriver, from the side of the smaller diameter, it is necessary to slightly lift the cover and equalize the pressure.
8. Place the sleeve clamp on the smaller diameter.
9. Inner joint: Press 120 g of VWG-6.3 grease into each side of the joint. If only the joint boot is being replaced, add grease as needed.
10. Press the inner joint in with a suitable press until it stops.
11. Install a new safety washer into the shaft groove using round-nose pliers.
12. Inner hinge: secure the protective cover with a sleeve clamp and attach a new gasket to the hinge, after removing the protective chamfer from it.
13. Install the axle shaft.
Visitor comments