Constant Velocity Joint Boot: Service and Repair
Drive shaft: replacing interior and exterior bellows
The following repair description applies to friction-welded drive shafts -A- and monobloc drive shafts -B-. The distinguishing feature is the diameter of the shaft. Friction-welded shafts -A- : approx. 28 mm in diameter/monobloc shafts: approx. 34 mm in diameter.
The replacement parts for friction-welded and monobloc shafts are different. Observe allocation as per Spare Parts Catalogue.
Replacing CV joints: only the transmission-side CV joint is supplied. Otherwise the entire shaft must be replaced.
In the case of monobloc shafts -B-, the position of the bellows -arrows- must be marked for reinstallation before disassembling the shaft. This ensures that the bellows will be reinstalled in the correct position. Use a colored pen or fabric tape to mark the position.
Replacing interior and exterior bellows (dust bellows)
^ Preliminary work: removing driving shaft
Assembly instructions for replacing bellows
Before disassembly, in monobloc drive shafts -B-, the correct position of the bellows must be marked for the reinstallation arrows-.
1. Remove the single-lug clamp and/or clip (depending on the design) -1 and 2-. Push bellows off profile shaft. Then force off closure cap -3- and bellows holder -4- evenly with a suitable mandrel -arrows-.
Do not remove bellows holder on wheel-side joint.
Replacing CV joints: only the transmission-side CV joint is supplied. Otherwise the entire shaft must be replaced.
2. Remove snap ring for CV joint with a suitable circlip pliers, e.g. circlip pliers vw 161 a.
3. Press off CV joint using special tools -A and B- plunger vw 408 a and thrust plate vw 401 a. Push dust bellows and bellows holder to the inner side of the drive shaft so that the CV joint can be pressed off.
4. Remove interior and exterior bellows.
5. Regrease the CV joint with special grease if necessary (refer to Spare Parts Catalogue). On the wheel-side joint, press the -special grease- through the bellows holder into the joint.
Do not remove bellows holder on wheel-side joint.
The CV joint must be able to be move slightly in an axial direction (length compensation).
6. Push interior and exterior bellows and clamps onto profile shaft.
7. Push or press CV joint onto the profile shaft in the correct position using a suitable pressure piece -C-.
8. Fit new snap ring.
9. Coat sealing surface of closure cap -arrow- and bellows holder with special sealant (refer to Spare Parts Catalogue).
10. Push on closure cap and bellows holder evenly from interior CV joint at congruent holes (holes for the fastening screws) with a plastic hammer (do not use force).
11. Position bellows. In monobloc drive shafts in accordance with the marking that was made previously -arrows-. In friction-welded drive shafts, between the relevant depressions.
12. Fit clip or single-lug clamp.
Clamp single-lug clamp using special pliers vag 1275 or a commercially available special pliers. If a single-lug clamp is used, place the lug of the hose clamp between two bores for the fastening screws.
A - Cut to separate
B - Cut to clamp