Caution: Depending on the engine/gearbox combination, the inner joint is designed as a constant velocity joint or «Tripode». Hinge «Tripode» instead of 6 balls, it has 3 rollers, which are offset by an angle of 120°relative to each other and are located on a star «Tripode».
External hinge
Withdrawal
1. Remove the shaft, refer to Section Removal and installation of a power shaft.
2. Clamp the shaft through the guards in a vise.
3. Remove the clamps and slide back the protective cover.
4. Screw in the pressure screw (3207) with thread guide M14/M16 into the hinge pin so as to remove the hinge from the shaft.
5. Remove the retaining ring.
Installation
1. Put the boot on the shaft.
Warning: The boot and its seat on the shaft must not be lubricated.
2. Install a new retaining ring.
3. Inject 50 g of grease into the inside of the hinge.
4. Screw the screw, which was previously used, into the hinge, as shown in the accompanying illustration.
5. Using a plastic hammer, press the joint onto the shaft until the circlip locks into place.
6. Remove the old screw.
7. Inject 40 g of lubricant into the hinge from the side of the boot.
8. Lubricate the outer pivot.
Warning: Observe the prescribed amount of grease, refer to Specifications.
Caution: The cover will often shrink when placed over the hinge body. In this case, a vacuum occurs in the hinge, which leads to the indentation of the cover (arrow on accompanying illustration). Therefore, when installing the boot with a small diameter screwdriver, fill the hinge with air so as to ensure pressure equalization.
9. Using special pliers, for example, HAZET 1847-1, compress the clamps on the large and small diameters of the hinge.
Plastic case
1. Compress the clamps on the large and small diameters.
2. Outer hinge: For clamping clamps (alloy steel) the special pliers HAZET 1847 shown in the illustration must be used, otherwise the required clamping force will not be achieved. The pliers must be installed as shown in the illustration. The working edges of the pliers should be in the corners (IN). In this position the screw (A) tightened with a torque of 20 Nm. The clamping of the clamp on a small diameter is carried out in a similar way.
Caution: The thread of the clamping screw of the pliers must be easy to move, otherwise it must be pre-lubricated with MoS2 grease. If the thread runs hard, for example due to contamination, the required screw tightening torque is not reached.
Internal constant velocity joint
Withdrawal
1. Remove the cover using a suitable punch.
2. Remove the retaining ring.
3. Remove grease from the joint and mark the position of the joint relative to the shaft.
4. Clamp the shaft by the joint in a vise, as shown in the accompanying illustration.
5. The assistant must hold the shaft horizontally so as not to damage it.
6. Use a small flat chisel to slightly fold the edge of the lid (arrow).
7. Install the cover in place using the appropriate mandrel.
8. Press the hinge off the shaft.
9. Remove cover with cover.
Installation
1. Apply lubricant to a clean surface of the inside of the cap (shaded surface in accompanying illustration). Apply a bead of sealant 2-3 mm wide around the holes on the inside. HUNDRED AUDI use sealant D 454 300 A2 for this.
Warning: Shaft, boot and adjacent surface must not be lubricated.
2. Put a new boot with a cover on the shaft.
3. Inject 85 g of lubricant into the case.
4. Secure the hinge with duct tape (arrow on accompanying illustration), so that it doesn't fall apart.
5. Press the hinge to the stop on the appropriate press. HUNDRED AUDI apply the special tool shown on an illustration for this purpose.
Caution: Install the pivot hub with a chamfer on the inner diameter (slots) on a hinge. The 40-204 A tool and the mating surface on the shaft must not be lubricated.
6. Install a new retaining ring.
7. Inject 35 g of lubricant through the ball tracks into the joint.
8. Align with screws (arrows) case with a cover in relation to the holes.
Warning: It is necessary to set very accurately, because. after assembly it will be impossible to do so.
9. Replace the cover with the cover using a plastic hammer.
10. Wipe off any escaping grease immediately.
11. Expose the new cover with screws (arrows) in relation to the bolt holes.
Warning: It is necessary to set very accurately, because. after assembly it will be impossible to do so.
12. Replace the cover with the cover using a plastic hammer.
13. Wipe off any escaping grease immediately.
14. Reinstall the drive shaft, refer to the appropriate Section.
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