Replacing the inner CV joint
On the wiring diagrams of both variants of the drive shafts of Audi models, the drive shaft for the installed automatic transmission comes with a CV joint and cannot be repaired. In the following description, it must be borne in mind that only the inner joint collar can be replaced on this shaft.
Subsequent operations must be carried out, guided by the drawings. The inner CV joint cannot be repaired and must be replaced if damaged. Please read the section at the beginning of this chapter regarding the use of hinges of various sizes before replacing. The hinge must also be removed if the protective sleeve needs to be replaced.
Drive shaft parts on models with automatic transmission
1 Shaft with joint
2 clamp
3 Cuff
4 Clamp
5 Cuff
6 Fastening clamp
7 Washer
8 Spacer
9 Retaining ring (is replaced)
1 outer CV joint
Drive Shaft Parts for Manual Transmission Models
1 outer CV joint
2 Attachment ring (is replaced)
3 Spacer
4 Washer
5 Clamp
6 Cuff
7 Clamp
8 Drive shaft
9 Cuff and cap
10 Washer
11 Inner CV joint
12 Gasket
13 Attachment ring (is replaced)
Clamp the drive shaft in a vise.
Using pliers of a similar shape (VW 161a) remove the circlip from the end of the inner CV joint. The retaining ring must always be replaced.
Using a punch, carefully knock the protective cap off the hinge. Place the punch in several places around the circumference so as not to deform the cap.
Place the shaft under the press and press the shaft through the hinge. The hinge should be located as close to the middle as possible.
Pull the spring washer off the shaft (not available on all shafts). At the same time, pay attention to the installation method, because. washer bent (installation see below).
Thoroughly clean the drive shaft before installing a new joint.
spring washer (if available) install on the shaft so that the bulge points to the shaft in a curved line.
Press the CV joint onto the shaft, supporting the shaft from below. The bevel on the inner diameter of the middle of the ball must be directed towards the thrust shoulder of the shaft. It is good to support the shaft from below and press the joint until it stops.
Insert a new circlip into the groove. If required, press it in with a special clamp.
Fill the joint with G6 grease. With a hinge diameter of 100 mm, 180 g of lubricant is required - 50 g per cuff (case) and 30g - in the hinge. With a hinge diameter of 108 mm, 30g of lubricant is required in the hinge, and 85g in the cuff. The grease must be tightly packed in order for the hinge to work properly. Mix the grease well in the joint.
Carefully hammer the protective cap back onto the hinge.
Put the collar on the drive shaft. In the workshop, special pliers are used to tighten the clamp. If they are not. Care must be taken when tightening the cuff so that the clamp does not come off. Before the cuff is closed. it needs to be squeezed a little to get out the air that got there. If, after assembly, retracted places are found, then loosen the cuff at a smaller diameter and carefully pry with a screwdriver to let in air and equalize the existing vacuum. In this case, of course, care should be taken not to damage the cuff with a screwdriver.
It is good to clean the shaft and cuffs, because. road dust and dirt quickly adhere to the lubricant.
Attention: The inner shaft joint for automatic transmission is filled with 14 g of grease G 00605. Only when replacing the seal, it is necessary to lubricate the joint again. Evenly distribute the grease between the joint and the collar.
Replacing the outer CV joint
Both the inner and outer CV joint can only be replaced completely. As mentioned above, the external joint varies between models with different engines. At the beginning of the chapter it is indicated what to look for and which hinge will have to be dealt with.
CV joint removal
Remove the clamps on both ends of the rubber cuff and pull the cuff along the shaft along the CV joint.
Clean the inside of the hinge.
Clamp the shaft in a vise with soft metal jaws (tin, aluminum) and knock the joint off the shaft with an aluminum or copper hammer so that it can be removed from the shaft, and the mounting spring inside popped out of the groove. At the shaft for automatic transmission, the parts must be marked in their original positions before removal.
CV joint installation
Put a rubber cuff on the shaft and slide along it.
Accurately distribute the used lubricant. With a hinge diameter of 89 mm, 40 g goes to the hinge, and 50 g of the above lubricant goes to the cuff. In the case of a CV joint of a different diameter - 80 g in the hinge, and 40 g in the cuff.
1 Retaining ring
2 Spacer
3 Spring washer
Slide a spring washer with internal teeth onto the shaft so that the bulge is at the hinge and the shim protrudes.
Put a new retaining ring on the shaft, clamp the shaft in a vise and hammer the hinge onto the shaft with a copper or aluminum hammer until the retaining ring enters the groove in the inner side of the hinge.
Pull the rubber cuff on the CV joint and strengthen with clamps. Before tightening the cuff, you need to squeeze it a little to squeeze out the air that has got there. If after assembly there are retracted places, then loosen the cuff back at a smaller diameter and carefully pry it off with a screwdriver so that air enters and the existing vacuum can be compensated. When prying off the cuff with a screwdriver, be careful not to damage the cuff.
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