Servicing

NOTE:
- Drive shafts on vehicles with Plus suspension have shorter and finer splines on the outer joint. The wheel bearing is secured by a 12-point nut.
- The splines of the outer joint and the hub on Plus suspensions are secured with locking fluid part No. D 185 400 A2, or equivalent.
- Drive shaft, removing and installing, refer to Replacement.
- Grease quantity:
- Outer constant velocity joint: 100 g of G-6.3, or equivalent, grease.
- Inner constant velocity joint: 110 g of G-6.3, or equivalent, grease.
- Greasing outer joint: press half of the grease into the joint, and the other half evenly into the boot.
- Greasing inner joint: press half of the grease into the inner joint from both sides, the other half evenly into the boot.
- When replacing the boot grease joint as required.
- Directly below the component legend are the Fig. numbers. Please refer to these for information regarding removal and installation instructions.






1 Outer constant velocity joint
- Replace complete
- Removing, refer to Fig. 1
- Installing: Drive onto the shaft with plastic hammer until circlip comes out
- Greasing, refer to notes above
- Checking. Testing and Inspection

2 Circlip
- Always replace
- Install in groove of shaft

3 Thrust ring

4 Dished washer
- Larger diameter (concave side) contacts thrust ring

5 Clamp
- Always replace
- Tightening, refer to Figs. 2 and 3

6 Boot constant velocity joint, 90 mm dia.
- Check for cracks and abrasion
- Before tightening the small clamp, ventilate boot briefly so pressure is equalized,, refer to Fig. 2

7 Clamp
- Always replace
- Tightening, refer to Figs. 2 and 4

8 Drive shaft, left, with inner tripod joint
- Repair of inner joint and replacement of boot not possible at this time
- Replace if damaged

9 Inner spliced screw, 45 Nm (33 ft. lbs.)

10 Drive shaft, right, with inner tripod joint
- Repair of inner joint and replacement of boot not possible at this time
- Replace if damaged

NOTE: For this procedure, use the tools shown in the following illustrations or their equivalents.





Fig. 1 - Constant Velocity Joint, Outer, Removing
- Drive off from drive shaft with forceful blow using an alloy hammer.





Fig. 2 - Boot, Ventilating
- The boot is pressed on forcefully when installing on the joint body.
- This creates a vacuum in the boot that makes a dent during driving -arrow-.
- Briefly ventilate the boot at the small diameter after installation to provide equalize pressure.





Fig. 3 - Clamp, Tightening On Large Diameter
- Install pliers VAG 1682 as in illustration. Ensure that the blades of the pliers lie in the corners -arrow -B- of the clamp.
- Tighten clamp by turning the spindle with a torque wrench (do not tilt pliers during this process).

NOTE: Because of the hard material (compared to rubber) of the boot and the stainless steel hose clamp that is necessary, only tighten the clamp with pliers VAG 1682.

- Tightening torque: 25 Nm (18 ft. lbs.)
- Use a torque wrench with an adjustment range: 5-50 Nm (e.g. tool No. VAG 1331, or equivalent)
- Ensure that threads of spindle on the pliers are easy to move. If necessary lubricate with MoS2 grease
- If difficult to move, e.g. dirt in the threads, the required tightening force of the clamp is not achieved with the specified torque.





Fig. 4 - Clamp, Tightening On Small Diameter