Drive shafts
Usually there are no problems with the drive shafts. Their service life, of course, depends on driving style. Sharp starts with the front wheels turned out and pulling away with slipping lead to premature failure of the hinges.
The driveshaft joints usually suddenly show signs of malfunction, which, however, may soon disappear completely again. «Quiet phase» can last for many days or kilometers.
cuffs (arrows) on the cardan joints of both drive shafts must not have cracks or other damage. Water and dirt are dangerous for the universal joint.
Characteristic are rhythmic pounding or knocking noises when pressing the accelerator pedal or when driving in forced idling mode (coasting). If the noise changes depending on the turn of the steering wheel, then the external hinge is most likely faulty (from the side of the wheel).
Vibrations and shaking of the steering wheel when the wheels are turned also indicate a faulty outer joint.
Removing the front drive shaft
You will need a new hex bolt with locking element for the driveshaft in the outer wheel hub, as well as a seal for the inner shaft joint (gasket is not needed for 6-cylinder engines with manual and automatic transmissions).
Remove the wheel cover and loosen the wheel bolts.
Loosen the hex bolt in the wheel hub; for this Audi must be fixed.
Raise the front of the vehicle and secure it and remove the wheel.
If equipped, remove the transmission drive shaft guard.
On models with ABS, pull back the speed sensor slightly.
Remove the socket head bolts securing the shaft to the gearbox.
Press driveshaft off gearbox flange.
To remove the shaft, turn out the steering accordingly.
Installation: install a new gasket on the inner homokinetic joint.
First insert the shaft from the side of the wheel. Then cross-tighten the fixing bolts on the drive flange on the gearbox side (bolts M8: 45 Nm; bolts M10: 80 Nm). Don't forget the seals for the homokinetic joints!
Lower the car, block the wheels. Tighten the new wheel hub bolts as follows:
Bolt M16x1.5: tighten to 200 Nm and finally tighten another ¼ turn (90°).
Tighten nuts on stabilizer link rod to 20 Nm.
On models with ABS, manually push in the speed sensor until it stops.
Removing the front drive shaft
You will need a new hex bolt with locking element for the driveshaft outer joint and a gasket for the inner shaft joint (gasket only for models with 5- and 6-cylinder engines)
Remove the wheel cover and loosen the wheel bolts.
Loosen the hex bolt in the wheel hub; for this Audi must be fixed.
Raise the front of the vehicle and secure it and remove the wheel.
If equipped, remove the transmission drive shaft guard.
On models with ABS, pull back the speed sensor slightly.
Remove the socket head bolts securing the shaft to the gearbox.
Press driveshaft off gearbox flange.
To remove the shaft, turn out the steering accordingly.
Installation: install a new gasket on the inner homokinetic joint.
First insert the shaft from the side of the wheel. Then cross-tighten the fixing bolts on the drive flange on the gearbox side (bolts M8: 45 Nm; bolts M10: 80 Nm). Don't forget the seals for the homokinetic joints!
Lower the car, block the wheels. Tighten the new wheel hub bolts as follows:
Bolt M16x1.5: tighten to 200 Nm and finally tighten another ¼ turn (90°).
Tighten nuts on stabilizer link rod to 20 Nm.
On models with ABS, manually push in the speed sensor until it stops.
Removing the rear drive shaft
You will need a new hex bolt with locking element for the driveshaft outer joint and a gasket for the inner shaft joint (gasket only for models with 5- and 6-cylinder engines).
Remove the wheel cover and loosen the wheel bolts.
Loosen the hex bolt in the wheel hub; for this Audi must be fixed.
Raise the car at the rear, secure it and remove the wheel.
Unscrew the hexagon socket screws securing the shaft to the rear axle differential.
Unscrew the disc brake caliper and tie it up high against the body together with the connected piping (see chapter «brakes»).
Remove brake disc (see chapter «brakes»).
Press propshaft off drive flange at gearbox.
Pull back the ABS speed sensor slightly.
Unscrew the axle arm (axis) independent wheel suspension at the top of the wheel bearing housing.
Loosen fixing bolt under suspension strut.
Press down the wheel bearing housing, remove the shaft.
Installation: install a new seal on the inner joint.
First insert the shaft from the side of the wheel. Then cross-tighten the fastening bolts on the drive flange from the inside (bolts M8: 45 Nm; bolts M10: 80 Nm). Don't forget the gaskets!
Mount the axle suspension again. Tighten the nuts for the independent suspension axle arm to 200 Nm, and for the suspension strut below, to 90 Nm.
Install the brake disc and disc brake caliper.
Tighten the new wheel hub bolt as follows: tighten to 200 Nm and finally tighten by another ¼ turn (90°).
Tighten nuts on stabilizer link rod to 20 Nm.
Manually push in the ABS speed sensor as far as it will go.
Note: Do not drive vehicles with the PTO shaft removed; otherwise the wheel bearing will be damaged. In an emergency, only the outer hinge should be installed. Audi vehicles have different drive shafts depending on the type of engine and gearbox. Therefore, when purchasing spare parts, have the engine marking and vehicle identification number with you.
Left: external driveshaft joint:
1 - retaining ring;
2 - spacer washer;
3 - Belleville spring.
Right: internal homokinetic hinge (2):
1 - lock washer;
3 - drive shaft.
Removing the outer hinge. All models
Remove drive shaft.
If the cuff is OK» bend the large clamp, push back the protective cuff.
If the cuff is damaged, remove it completely.
Make a strong blow from the inside on the hinge with an aluminum or plastic hammer and thus move the hinge off the shaft.
Before installing a new joint, insert a new retaining ring into the groove of the input shaft.
Install the Belleville spring and spacer, if they were installed in the respective drive shaft version, as shown in the figure above. Don't forget the rubber cuffs!
When installing, drive the joint onto the shaft with a plastic hammer until the circlip locks into place.
Lubricate the hinge: a new hinge with an outer diameter of 80 or 90 mm needs 90 g of MoS2 (VW G 6), while 40 g in the hinge and 50 g in the cuff.
Joints with an outside diameter of 98 mm require more grease: 120 g MoS2 (VW G 6), while 80 g in the hinge and 40 g in the cuff.
If already used hinges are installed, it is only necessary to add lubricant to them.
Firmly compress the cuff clamps.
Removing the inner hinge. Homokinetic hinge
Remove drive shaft.
Using two narrow screwdrivers, pry the retaining ring that holds the joint to the drive shaft from the groove on the end of the shaft and remove it.
Now pull the hinge off the shaft; if necessary, help yourself with a plastic or aluminum hammer.
If the hinge cannot be removed from the shaft, it will have to be pressed out with a repair press in the workshop.
When installing, put on the cuff first.
If your car has a hinge with a belleville spring, then before installing it, you need to put the spring on the shaft or check its position: along the outer edge it should be bulging towards the hinge.
Put the hinge on the axle shaft, install the retaining ring.
In order for the retaining ring to fall into the groove, you need to clamp the axle shaft in a vice, install a large replacement socket head or a piece of pipe over the inside of the hinge and hit it sharply with a hammer. The hinge will move back a little, bending the spring, and the retaining ring will enter the groove.
Lubricate the joint: a new joint with an outer diameter of 100 mm needs 90 g of MoS2 (VWG 6), while 40 g in the hinge and 50 g in the cuff.
Joints with an outside diameter of 108 mm require more grease: 120 g MoS2 (VW G 6), while 35 g in the hinge and 85 g in the cuff.
In already used cardan joints, it is only necessary to add grease.
Before screwing the hinge (or cuff flange) coat the sealing surface between the oil seal flange and the joint with sealing agent VW D 3.
Removing the inner hinge. Hinge «tripod»
hinges «tripod» cannot be separated from the drive shaft. As spare parts, they are supplied complete with axle shaft and protective collar. Thus, when replacing, it is necessary to remove the outer joint and replace the shaft with the inner joint.
If only the protective cuff of the hinge is defective «tripod», then first you need to remove the outer hinge. On the cleaned drive shaft, the cuff can be moved to the hinge «tripod». Critical point: The seal must be lifted over the boss in the middle of the shaft To do this, grease the boss with grease and lift the seal over the boss with a blunt round tool (spoon handle).
The joint contains 140 g of grease G 000 605. Only a small amount of grease needs to be added when changing the seal.
Cardan joint «tripod» (1) cannot be separated from the drive shaft. Homokinetic joints, on the other hand, can be removed from the actual drive shaft (3) - as external (2), as well as internal (4).
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