1. Remove the axle shaft.
2. Unclench the cuff fastening collar on the faulty CV joint and move the cuff onto the shaft. If the cuff is damaged, remove it.
3. Knock the CV joint off the shaft with an aluminum or plastic hammer.
4. Install a new retaining ring in the groove on the shaft before installing the new joint.
5. Install the disc spring and spacer, if any, on the type of CV joint being repaired (see illustration).
6. Stuff the hinge onto the shaft. The retaining ring should then fall into place.
7. Pack grease into the joint. New 81mm or 88mm OD pivot includes 90g of molybdenum grease (VW G 6), including 40 g of the indicated amount are stuffed into the hinge itself, and 50 g into the cuff. More grease is needed for hinges with an outer diameter of 98 mm: 120 g. Of these, 80 g are stuffed into the hinge, and 40 g into the cuff.
If the previous CV joint is installed, then lubricant should only be added to it.
8. Secure the cuff to the hinge with a clamp.
Internal universal joint of equal angular speeds - removal and installation
9. Remove the axle shaft.
10. Remove the circlip holding the pivot to the shaft from the end of the shaft using two small screwdrivers.
11. Remove the hinge from the shaft. If necessary, knock it down with a plastic or aluminum hammer. If the hinge does not give in, then it must be pressed out using the services of a workshop.
Before installing the CV joint in place, put on the cuff on the shaft.
12. Install the disc spring or check its position, if any, for the repaired type of CV joint (see illustration 12.5). The spring should be facing the convex side of the hinge.
13. Install the hinge on the shaft and fix it with a retaining ring. To perform this operation, the shaft should be clamped in a vice, the hinge should be filled with an appropriate mandrel or a pipe of suitable diameter. At the same time, the hinge will overcome the resistance force of the disk spring and will shift on the shaft, the locking disk will become in the groove (see illustration).
14. Pack grease into the joint. New 90mm or 100mm OD swivel includes 90g of molybdenum grease (VW G 6), including 40 g of the indicated amount are stuffed into the hinge itself, and 50 g into the cuff. A larger amount of grease is needed for hinges with an outer diameter of 108 mm: 120 g. Of these, 35 g are stuffed into the hinge, and 85 g into the cuff.
If the old CV joint is installed, then lubricant should only be added to it.
15. Apply to the contact surface of the CV joint (cuffs) VW D3 sealing compound to the mounting flange on the gearbox before attaching the axle shaft to the flange.
Internal hinge «tripod» - removal and installation
hinges «tripod» cannot be removed from the shaft. In case of failure of the hinge, its replacement is carried out complete with a shaft and a cuff. When replacing the hinge, the outer hinge on the shaft is dismantled.
If only the protective cuff of the hinge is damaged «tripod», then to install a new cuff, it is necessary to remove the outer hinge. New cuff for «tripod» put on from the side of the removed outer hinge. The movement of the cuff along the shaft is prevented by the thickening of the shaft. In order not to damage the cuff, lubricate this thickening with a blunt round object (spoon handle) lift the cuff over the bulge.
16. Stuff in new «tripod» 140 g of grease G 000 605. When installing the old hinge, just add grease to it (see illustration).
12.16 CV joint
1 - hinge «tripod»
2 - external cardan joint of equal angular speeds
3 - drive shaft
4 - internal universal joint of equal angular velocities
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