Volkswagen Golf Service & Repair Manual: Dismantling and assembling drive shaft

Special tools and workshop equipment required

Thrust plate -VW 401-

Thrust plate -VW 402-

Press tool -VW 408 A-

Press tool -VW 411-

Tube -VW 416 B-

Thrust washer -VW 447 H-

Circlip pliers -VW 161 A-

Torque wrench -V.A.G 1331-

Torque wrench -V.A.G 1332-

Special pliers -V.A.G 1682-

Assembly tool -T10065-

Dismantling

Driving off outer constant velocity joint

Clamp drive shaft in vice using protective jaw covers.
Remove clamps.
Fold back boot.
Drive constant velocity joint off drive shaft using drift -A-.

Drift must be positioned exactly on ball hub of constant velocity joint.

Driving joint on

Installation position of dished spring at outer joint

1 -	Dished spring

Insert new circlip.
Use plastic-headed hammer to drive joint onto shaft until circlip engages.

Driving off cover for inner joint

Pressing off inner constant velocity joint

Press off protective boot off joint using a drift.
Remove retaining ring.
Remove both clamps and slide boot towards outer joint.

Assembling

Installation position of dished spring at inner joint

1 -	Dished spring

Pressing on inner constant velocity joint

Note Chamfer on internal circumference of ball hub (splines) must face contact shoulder on drive shaft.

Press joint on to stop.
Install retaining ring.

Using bolts -arrows-, align new cover in relation to bolt holes.

The alignment must be very accurate, because no further alignment is possible once the part has been hammered on.

Drive on cover using a plastic hammer.

Tighten clamp on outer joint

Position clamp tensioner -V.A.G 1682- as shown in diagram. Ensure jaws of tensioner lie in corners -arrows B- of ear on O-type clip.
Tighten clamp by turning spindle with a torque wrench (do not cant pliers).

Note Due to the hard material of the protective boot (compared to rubber) and the necessity of using a stainless steel clamp, it is only possible to tension the clamp with clamp tensioner -V.A.G 1682-.

Specified torque: 25 N·m.

Use torque wrench -C - with setting range of 5 ... 50 N·m. Make sure thread of spindle -A- on pliers moves freely. Lubricate with MoS2 grease if necessary. If the thread is tight (e.g. due to dirt), the required clamping force for the clamp will not be attained although the specified tightening torque is applied.

Dismantling and assembling drive shaft