Attention. Depending on the engine/gearbox fitted to the vehicle, the internal constant velocity joint can be a ball joint or a roller joint (tripoid). In the roller joint, instead of six balls, three rollers are used, located at an angle of 120°, mounted on a three-arm holder. The roller joint is not replaced separately, and if it fails, it must be replaced together with the drive shaft.
Disassembly
Remove the drive shaft from the vehicle.
Secure the drive shaft in a soft jaw vise.
Remove or cut the protective boot clamps and slide the boot from the hinge onto the drive shaft.
Screw in special tool 1 (pic. 7.21) VAG-3207 with M14 or M16 threads into the joint shaft and screw the tool until the outer joint is removed from the drive shaft.
Internal ball joint
The internal CV joint cannot be repaired, and if it fails, it must be completely replaced.
Secure the drive shaft in a soft jaw vise.
Using special VAG-161a or HAZET 2525K circlip pliers, remove the circlip from the end of the inner constant velocity joint.
Using a mandrel, remove the protective cover of the hinge with the flange. The mandrel must be installed in turn at various points along the perimeter of the flange, for its uniform removal. Move the protective cover onto the drive shaft.
Place the joint under the press and, using a round tool, press the drive shaft out of it, while supporting the inner bushing of the joint (see fig. 7.22).
Clean the hinge from grease.
Assembly
Replace damaged protective covers. To do this, remove the protective cover by sliding it along the drive shaft, while to facilitate the removal of the cover, a thin layer of grease can be applied to the drive shaft.
Internal ball joint
Secure the inner CV joint in a soft jaw vise and insert the drive shaft into it. If the shaft does not fit into the hinge, press the hinge onto the shaft using a press, while the shaft from below must rest on the support (see fig. 7.23). Check that the chamfer of the inner joint bush must be on the side of the drive shaft
Using special pliers VAG-161a or HAZET 2525K, install a new snap ring into the groove of the drive shaft.
Fill the inner hinge and protective boot with grease.
Apply VW-sealant D-3 to the end surface of the flange of the protective boot of the joint and install the protective boot with the flange on the joint.
Remove the protective film from the new gasket and glue the gasket to the hinge.
Install a small clamp on the protective cover and fasten it with HAZET1847-1 tongs.
Slide the protective cover of the outer constant velocity joint onto the drive shaft.
Install the Belleville washer on the drive shaft with the convex side towards the pivot and the thrust washer (see fig. 7.24).
Install a new snap ring on the drive shaft, fix the shaft in a vice with soft jaws and use an aluminum or copper hammer to drive the joint onto the drive shaft, while the lock ring should fit clearly into the groove on the inside of the joint.
Install the protective cover on the hinge. Depending on the model, protective covers can be made of rubber or plastic.
Rubber protective boot
When installing a protective cover on the hinge, as a result of its compression, the air pressure inside the cover is usually lower than atmospheric pressure, as a result, wrinkles appear on the cover (see fig. 7.25). To equalize the air pressure under the protective cover, use a screwdriver to lift the cover from the side of the drive shaft.
Secure the protective cover with new clamps. HAZET 1847-1 tool is required to fasten the clamps (see fig. 7.26).
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