Volkswagen Golf Service & Repair Manual: Dismantling and assembling drive shaft, constant velocity joint VL100

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-

Multi-purpose tool -VW 771-

Puller -T10382-

Removing outer constant velocity joint

Clamp drive shaft in vice using protective jaw covers.
Fold back boot.
Set puller -T10382- up so that smooth side of puller plate -T10382/1- points to spindles -T10382/2-.
Assemble puller -T10382- complete with multi-purpose tool -VW 771-.

Pull constant velocity joint from drive shaft with puller -T10382- and multi-purpose tool -VW 771-.

1 -	Puller plate -T10382/1-

2 -	Spindles -T10382/2-

Driving on outer constant velocity joint

Installation position of dished spring and thrust washer on outer joint

1 -	Dished spring

2 -	Thrust washer

Install new retaining ring.
If necessary, push new joint boot onto drive shaft.
Knock onto shaft with plastic hammer until circlip engages.

Pressing off inner constant velocity 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.

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, constant velocity joint VL100