Constant Velocity Joint Boot: Service and Repair
Replacing bellows drive shaft
Information
The following repair description applies to friction-welded drive shafts -1- and monobloc drive shafts -2-. The distinguishing feature is the diameter of the shaft. Friction-welded drive shafts -1- approx. 28 mm in diameter/monobloc drive shafts -2- approx. 34 mm in diameter.
The replacement parts for friction-welded and monobloc drive shafts are different.
Replacing CV joints: only the transmission-side CV joint is supplied. Otherwise the entire drive shaft must be replaced.
In the case of monobloc drive shafts -2-, 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.
Overview of drive shaft
1 - Friction-welded drive shaft
2 - Monobloc drive shaft
Replacing bellows drive shaft
Drive shaft disassembled
1 - Clamp or clip, small
2 - Clamp or clip, large
3 - Lid
4 - Halfshaft flange
5 - Circlip
6 - CV joint
7 - Boot
8 - Clamp or clip, small
9 - Clamp or clip, large
10 - Boot
11 - Profile shaft
1. Mark drive shafts.
Marking drive shaft
Required only for monobloc drive shafts: before disassembling the shaft in the case of monobloc drive shafts, the correct position of the bellows must be marked for reinstallation -arrow-.
Do not remove bellows holder on wheel-side joint.
Replacing CV joints: only the transmission-side CV joint is supplied. Otherwise the entire drive shaft must be replaced.
2. Remove CV joint on transmission side.
Circlip pliers
2.1. Remove circlip for CV joint using suitable circlip pliers, e.g. circlip pliers vw 161 a.
Pressing off CV joint
2.2. Press off CV joint using special tools -1, 2- plunger vw 408 a and pressure 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.
Outer CV joint
3. Remove outer bellows.
3.1. Remove clamp and/or clip (depending on the design) -1 and 2-.
3.2. Push bellows off profile shaft. Then force off lid -3- and bellows holder -4- evenly with a suitable mandrel.
4. Grease CV joints.
Regrease the CV joints with special grease if necessary. On the wheel-side joint, press -the special grease- through the bellows holder into the joint.
Greasing CV joint
Do not remove bellows holder on wheel-side joint.
The CV joints must be able to be move slightly in an axial direction (length compensation).
5. Push inner and outer bellows and clamps or clips onto profile shaft.
6. Install CV joints.
Pressing on CV joint
6.1. Push or press CV joint onto the profile shaft in the correct position using a suitable pressure piece -3-.
Circlip pliers
6.2. Use new circlip.
Install circlip for CV joint with suitable circlip pliers, e.g. circlip pliers vw 161 a.
7. Install lid.
Greasing lid
7.1. Coat sealing surface of lid -arrow- and bellows holder with special sealant.
7.2. Push on lid and bellows holder evenly from inner CV joint at congruent holes (holes for the fastening screws) with a plastic hammer (do not use force).
Marking drive shaft
8. Position and secure bellows.
8.1. In monobloc drive shafts in accordance with the marking that was made previously -arrows-. In friction welded drive shafts, between the relevant depressions.
8.2. Tighten clips or clamps.
Tighten the clamps using the special pliers vag 1275 or a commercially available special pliers.