Note: This operation will require a long M16 bolt/threaded stud (see item 4).
2. Fix the shaft in a vice with soft jaws, then remove the clamps for fastening the covers. If necessary, cut the clamps.
3. Flip the cover back to expose the hinge. Collect excess grease and dispose of it.
4. Now you need to remove the outer joint from the shaft. To do this, it is best to use a long bolt or M16 stud. Screw the bolt into the hinge thread until it stops against the shaft, then, overcoming resistance, compress the hinge (pic. 3.4).
Note: If the original bolt has a full length thread, you can use that too.
If a bolt or stud is not available, a hammer and a suitable soft punch can be used to knock the joint off the shaft - be careful not to damage the joint.
On models with hollow shafts, you will need to slide the inner circlip out of the groove on the inner surface of the joint so that the Belleville washer and plastic sleeve can be removed from the shaft.
5. With the hinge removed, remove the circlips from the groove in the splined end and discard them. New rings are required for installation.
6. Remove the bushing and Belleville washer from the shaft, noting how they were installed. Remove the rubber boot.
7. After removing the joint from the shaft, wash it thoroughly with kerosene or other suitable solvent and dry it. Examine the hinge.
8. While tilting the inner drive spline to expose the balls, inspect them for nicks or nicks.
9. Carefully inspect the working surfaces of the outer and inner races. If the tracks are broken, the balls will no longer fit tightly. At the same time, inspect the separator windows - there should be no wear, cracks, breaks or other damage.
10. If the hinge is worn or damaged, replace it or (if the hinges are not sold separately) the whole shaft. Check with your dealer for availability of spare parts. The original Audi/VAG repair kit consists of a new boot, circlip, clamps, washer, bushing and the required amount of grease of the prescribed type.
11. Wrap the splines of the shaft with tape and put a new cover on it (pic. 3.11). Remove the tape.
12. Install the Belleville Washer with the convex face inward and then the Bushing with the flat face towards the washer (pic. 3.12, a, b).
13. Install a new retaining ring in the groove of the shaft (pic. 3.13).
14. Spread grease over the hinge, then squeeze the remaining grease into the boot (pic. 3.14).
15. Install the outer joint on the splines of the shaft and slide it all the way into the retaining ring. Gently but firmly tap the end of the splined pivot pin with a soft, heavy hammer to snap it onto the retaining ring (pic. 3.15, a, b). Pull on the hinge to make sure it is secure.
16. Place the outer edge of the boot into the groove of the outer hinge and lift the inner edge to equalize the air pressure inside the boot (pic. 3.16).
17. Install the clamps on both ends of the covers and squeeze the protruding part to tighten the clamps. If there is no special tool, you can do it carefully enough with wire cutters (on overdo it - do not bite the clamp) (pic. 3.17, a-c).
18. Check the freedom of movement of the hinge in all directions and install it on the car, as described in paragraph 2.
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