Note: The inner joint has a very tight fit on the shaft and requires a hydraulic press to remove. If there is no such equipment, the replacement of the cover can be entrusted to the specialists of the dealer car service or the craftsman of an untested garage.
19. Secure the shaft in a vice with soft jaws and a hammer through a simpleton, carefully knock the cover fixing plate off the outer race of the inner hinge (pic. 3.19).
Pic. 3.19. Driveshaft Components - Gasoline Models with Manual Transmissions: 1. Retaining ring; 2. Gasket; 3. Internal hinge; 4. Inner case and fixing plate; 5. Drive shaft; 6. Collar; 7. Outer case; 8. Collar; 9. Belleville washer; 10. Sleeve; 11. Retaining ring; 12. External hinge
20. Remove the circlip from the inner end of the shaft.
21. Remove the inner joint from the shaft by firmly resting the outer race and pressing the shaft out of the inner one.
22. Remove the inner collar of the boot and remove the boot from the shaft.
23. Clean and inspect the inner hinge as described in p.p. 7...9.
24. If the joint is worn or damaged, replace it or the entire shaft - check with the dealer for availability of spare parts. If the hinge is in working order, purchase a repair kit that consists of a new boot, retaining ring, clamps, washer, bushing, and the required amount of prescribed type of grease.
25. Wrap the pins with tape and put a new cover on the shaft. Remove the tape and install the fixing plate on the case.
26. Securely rest the shaft and press the inner joint onto it. Secure the joint to the shaft with a new circlip by fitting it into the groove.
27. Spread grease over the hinge, then squeeze the remaining grease into the boot.
28. Wipe clean the mating surfaces of the boot fixing plate and hinge. Apply a layer of sealant (Audi/VAG recommend D3 sealant - available from dealer) on the fixing plate. Align the holes in the plate with the holes in the outer race of the hinge and press the plate onto the cage.
29. Make sure that the outer edge of the boot is correctly fixed and lift the inner edge to equalize the air pressure in the boot with atmospheric pressure.
30. Install both clamps and squeeze the protrusion to tighten the clamps. If there is no special tool, you can do it carefully enough with wire cutters (do not overdo it - do not bite the clamp).
31. 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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