Drive Axles, Servicing

Drive Axles, Servicing





Note:
^ The joints are provided with high-temperature grease G000633.





Re-grease joint, if necessary, when replacing the joint protective boot.

1 - Circlip
^ Remove and install using commercially available circlip pliers
2 - Gasket
^ Replacing. Pull off protective foil and stick self-adhering side of gasket onto joint.
3 - Inner constant velocity joint
^ Outside diameter: 108 mm
^ Only replace complete
^ Pressing off, refer to Fig. 1
^ Pressing on, Refer to Fig. 2
4 - Protective boot for inner constant velocity joint
^ With vent hole
^ Check for tears and chafing
^ Drive off with drift
^ Before Installing on constant velocity joint, coat sealing surface with D 454 300 A2 housing sealant
5 - Profiled shaft
^ Same length on left and right
6 - Protective boot
^ Check for tears and chafing
7 - Hose clamp
^ Always replace
^ Tightening, Refer to Fig. 3
8 - Dished washer
^ Installation position, Refer to Fig. 5
9 - Spacer ring (plastic)
^ Installation position, Refer to Fig. 5
10 - Circlip
^ Always replace
^ Insert in shaft groove
11 - Outer constant velocity joint
^ Outside diameter: 98 mm
^ Only replace complete
^ Removing, Refer to Fig. 4
^ Installing:
- Drive onto shaft with plastic hammer until circlip engages





Fig. 1 Pressing off inner constant velocity joint
^ Insert circlip.
^ Use mandrel to drive off boot.

Note: Support ball hub with plate VW 402.





Fig. 2 Pressing on inner constant velocity joint
^ Press on joint up to stop.
^ Insert circlip.

Note: Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.





Fig. 3 Tightening hose clamp





Fig. 4 Pressing off outer constant velocity joint
^ Clamp drive axle in vise.
^ Remove the large hose clamp and pull back boot.
^ Screw special tool 3207 into end of joint until constant velocity joint can be removed from shaft.





Fig. 5 Installation positions of spacer ring and dished washer (wheel side)
1 - Dished washer
2 - Spacer ring (plastic)