1 circlip
2 internal CV joint
External diameter on engines with power:
- 55-66 kW: 90 mm;
- 82-85 kW: 100 mm;
- 100-125 kW: 108 mm.
CV joint must only be replaced as a set.
3 seal
Only available on 82-125 kW engines.
4 cup spring
Not available on 100 kW engines.
5 hinge guard with cover
6 shaft
Has a different length depending on the version of the gearbox
7 clamp
8 hinge guard
9 clamp
10 Belleville washer
11 spacer
12 retaining ring
13 outer constant velocity joint
Disassembly
Remove drive shaft.
Cut and remove the clamps on both hinge covers using side cutters. Slide the protective covers back.
Outer hinge: knock the hinge off the drive shaft with a strong blow with a light metal hammer.
Internal hinge: Use a suitable punch to knock the protective cover off the hinge.
Internal hinge: remove the circlip using pliers, for example: VW-161a or HAZET 2525K.
Press in the inner joint with a suitable press while resting on the inner hub.
Remove the belleville spring and guard from the shaft.
Attention: Belleville springs are available both with and without toothing. When installing, use a new spring of the same design. For vehicles with 100 kW engine (136 HP) there is no disc spring.
Inner joint: for 82-100 kW motors (112-136 hp) remove additional seal.
Assembly
Replace fragile or defective protective covers.
Push on the shaft a protective cover with a collar of the internal hinge.
Inner joint: fit the disc spring onto the shaft, taking into account the correct position. The large diameter of the belleville spring rests on the hinge.
Lubricate the inner joint:
- 55-85 kW engine: 90 g G6 grease 45 g each side
- engine 100 kW up to 190: 120 g grease G6
- engine 100-125 kW from 2.90: 250 g grease G000604
If only the hinge guard is being replaced, if necessary, only add grease to the hinge.
Press the inner joint on the press until it stops.
Attention: Chamfer on the inner diameter of the ball ring (teeth) must face towards the adjacent projection on the drive shaft.
Insert the retaining ring into the shaft groove using VW 161a or HAZET 2525K.
Inner joint: Coat the clean front side of the joint housing cover with VAG D3 sealant. Screw the cover onto the bearing.
Install the outer bearing cap with clamp and clamp onto the shaft.
Lubricate the outer joint:
- engine 55-100 kW: 90 g of grease G6, 40 g to press into the constant velocity joint; 50 g evenly injected into the protective cover of the hinge;
- 125 kW motor: 120 g of G6 grease, 80 g to press into the constant velocity joint; 40 g evenly injected into the protective cover of the hinge.
If only the casing is being replaced, just add grease to the hinge.
Place the cup spring -3- and spacer -2- on the shaft in the correct position. The larger diameter of the Belleville spring rests against the spacer. The spacer washer faces the hinge.
Insert a new retaining ring into the groove of the shaft. Tap the circlip onto the shaft with a rubber mallet until it snaps into place in the groove.
Drive the constant velocity joint onto the shaft with a polymer or light metal hammer until the retaining ring snaps into place.
Install the protective cover of the hinge in the correct position, tighten the clamp
Attention: Often when putting on a cover on a body of the hinge it is pressed. Because of this, a reduced pressure arises in the cover, which, when moving, forms an internal fold. Therefore, after installing the boot, you should lift the boot at the small diameter with a screwdriver to let air in to equalize the pressure.
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