Inner joint (all models with automatic transmission) — repair (Audi A4 B5)

Note: Check with your dealer for parts availability - at the time of writing, only 32mm shaft inner boots were available as parts.

32. Remove the outer joint as described in p.p. 2...6it is recommended to replace the outer cover as well (in preventive chains), regardless of its condition.

33. Loosen the clamps and pull the inner joint boot off the drive shaft. If necessary, the boot can be cut - this will make the task easier.

34. Wash the joint thoroughly with kerosene and dry. Check the tripod bearings for wear and damage. The bearing rollers should rotate smoothly and without jamming (Fig. 3.34).



35. If the joint is found to be unusable, the entire shaft is replaced, since the joint is not supplied separately as spare parts. If the joint is in satisfactory condition, it is advisable to purchase a repair kit, which consists of a new boot, a retaining spring ring, clamps, a washer, a bushing and the required amount of grease of the prescribed type. Although this is not absolutely necessary, replace the outer joint boot as well, regardless of its condition.

36. Fill the joint with grease. Distribute it evenly over the joint by turning it (Fig. 3.36).





37. Clean the shaft with sandpaper from rust and burrs so as not to damage the cover during installation. Wrap the splines with tape and lubricate the shaft protrusions for the same purpose.

38. Place the new cover on the shaft and carefully pry it over the protrusion on the shaft, being careful not to damage the cover (fig. 3.38, a, b).


39. Place the outer edge of the boot into the groove of the outer race and the inner edge into the groove on the shaft.






39. Lift the inner edge to equalize the air pressure in the cover with the atmospheric pressure. Install both clamps and squeeze the protruding part to tighten the clamps. If you do not have a special tool, you can do this quite carefully with nippers (don't overdo it - don't bite the clamp).

40. Install the inner hinge as described p.p. 11...17 (Fig. 3.40).





41. Check the freedom of movement of the joint in all directions and install it on the vehicle - see paragraph 2.