Constant Velocity Joint Boot: Service and Repair

WM 422855 Replacing bellows drive shaft

Tools










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. Observe allocation as per spare parts catalogue.

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 coloured pen or fabric tape to mark the position.





Overview of drive shaft






Replacing bellows drive shaft





Drive shaft disassembled





1. Mark drive shafts.
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-.





Marking drive shaft

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.
2.1. Remove circlip for CV joint using suitable circlip pliers, e.g. circlip pliers VW 161 a.





Circlip pliers

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.





Pressing off CV joint

3. Remove outer bellows.





Outer CV joint

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 (refer to spare parts catalogue). 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.
6.1. Push or press CV joint onto the profile shaft in the correct position using a suitable pressure piece -3-.





Pressing on CV joint

6.2. Use new circlip.





Circlip pliers

Install circlip for CV joint with suitable circlip pliers, e.g. circlip pliers VW 161 a.
7. Install lid.
7.1. Coat sealing surface of lid -arrow- and bellows holder with special sealant (refer to spare parts catalogue).





Greasing lid

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).
8. Position and secure bellows.





Marking drive shaft

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.