Drive shaft, servicing

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1 Volkswagen Passat B6 - Drive shaft, servicing Стр. 1 из Drive shaft, servicing Drive shafts, overview I - Assembly overview: Drive axle with CV joint VL , Drive axle with CV joint VL100, assembly overview II - Assembly overview: Drive axle with CV joint VL , Drive axle constant velocity (CV) joint VL107, assembly overview III - Assembly overview: Drive axle with Triple-roller joint AAR2600i 40-7, Drive axle with Triple-roller joint AAR2600i, assembly overview IV - Assembly overview: Drive axle with Triple-roller joint AAR3300i 40-

2 Стр. 2 из 41 7, Drive axle with Triple-roller joint AAR3300i, assembly overview Difference of drive axles in installed condition VL100 VL107 AAR2600i AAR3300i Diameter of inner joint in mm Cover between inner joint and flange shaft - X - - Inner joint inserted into the transmission (only automatic transmission) - - X X Inner joint fastened to flange shaft of transmission (only manual transmission and direct-shift transmission) X X - X Fastening drive axle bolt, loosening and tightening Special tools, testers and auxiliary items required Angle wrench V.A.G 1756 The wheel bearings must not be loaded when drive axle fastener on wheel side is loose. If bearings are loaded by vehicles own weight the wheel bearing will be damaged. The wheel bearings will be stressed and life expectancy reduced. Therefore, observe the following: Procedure for loosening bolt. Vehicles without drive axle must not be moved, otherwise wheel bearing will be damaged. If vehicle must be moved, observe the following: - Instead of drive axle, install an outer joint.

3 Стр. 3 из 41 - Tighten outer joint to 120 Nm. Loosen hex bolt. - With vehicle sitting on its wheels, loosen bolt up to 90, otherwise wheel bearing will be damaged. - Lift vehicle until wheels hang freely. - Apply brake (second technician required). - Remove bolt - arrow -. Tighten hex bolt. - Replace bolt Note: To tighten the drive axle, the wheels must still not touch the floor; otherwise the wheel bearing can be damaged. - Apply brake (second technician required). - Tighten bolt to 200 Nm. - Lower vehicle onto its wheels. - Turn bolt an additional 180. Drive axle, removing and installing Special tools, testers and auxiliary items required

4 Стр. 4 из 41 Torque wrench V.A.G 1332 Angle wrench V.A.G 1756 Caution! When disassembling and performing repairs on vehicle, the drive axles must not be allowed to hang down and contact the stops in the joint by overflexing. Drive axle with constant velocity (CV) joint, removing - Loosen drive axle hex bolt 40-7, Fastening drive axle bolt, loosening and tightening. Note: The vehicle must not be sitting on its wheels, otherwise the wheel bearing can be damaged. - Remove lower sound insulation Repair Manual, Body Exterior, Repair Group 50, Sound insulation - Assembly overview

5 Стр. 5 из Disconnect axle shaft from transmission axle flange. - Remove wheel. - Push outer joint out of wheel hub by hand. - Remove nuts - arrows -. - Pull wheel bearing housing with ball joint out from control arm. - Pull drive axle out of wheel hub. Drive axle with constant velocity (CV) joint, installing Remove any paint residue and/or corrosion on thread/splines of outer joint. - Install drive axle. - Insert outer joint as far as possible into spline in wheel hub. - Fasten ball joint to control arm - arrows -. Note: Check boot for damage or twisting.

6 Стр. 6 из 41 - Install inner joint of drive axle and initially tighten bolts diagonally to 10 Nm. - Tighten multi-point socket head bolts diagonally to torque specification listed. - Install lower sound insulation Repair Manual, Body Exterior, Repair Group 50, Sound insulation - Assembly overview. - Tighten drive axle hex bolt. Note: The vehicle must not be sitting on its wheels, otherwise the wheel bearing can be damaged. - Install and fasten wheel 44-2, Torque specification for mounting wheels. Torque specifications specifications 40-3, Front axle, torque Drive axle with Triple-roller joint AAR2600i and AAR3300i (mated), removing - Loosen drive axle hex bolt 40-7, Fastening drive axle bolt, loosening and tightening. - Remove wheel. - Remove lower sound insulation Repair Manual, Body Exterior, Repair Group 50, Sound insulation - Assembly overview.

7 Стр. 7 из 41 - Remove nuts - arrows -. - Pull wheel bearing housing with ball joint out from control arm. - Pull drive axle out from wheel hub and secure it to body. - Place wedge tool T10161 between transmission housing and triple-roller joint. - By hitting wedge tool T10161 with a hammer, press inner joint out of transmission. - Remove drive axle. Drive axle with Triple-roller joint AAR2600i and AAR3300i (mated), installing - Install new circlip into groove of joint shank. - Engage outer and inner splines of joint and transmission. - Grab drive axle by hand and push it into joint up to stop. - Now push joint into transmission with a "jolt". The sliding part in joint can be used for this "jolt". When doing this, do not pull drive axle too far out of joint. Note:

8 Стр. 8 из 41 Do not use a hammer or other impact tool under any circumstances! - Verify that the drive axle is securely seated in transmission, by pulling joint against resistance of circlip. For this check, do not pull on drive axle, but rather only on joint. - Insert outer joint as far as possible into spline in wheel hub. - Install lower sound insulation Repair Manual, Body Exterior, Repair Group 50, sound insulation - Assembly overview. - Fasten ball joint to control arm - arrows -. Note: Check boot for damage or twisting. - Tighten drive axle hex bolt. Note: The vehicle must not be sitting on its wheels, otherwise the wheel bearing can be damaged. - Install and fasten wheel 44-2, Torque specification for mounting wheels. Torque specifications specifications 40-3, Front axle, torque

9 Стр. 9 из 41 Drive axle with Triple-roller joint AAR3300i (bolted), removing - Loosen drive axle hex bolt 40-7, Fastening drive axle bolt, loosening and tightening. - Remove wheel. - Remove lower sound insulation Repair Manual, Body Exterior, Repair Group 50, Sound insulation - Assembly overview. - Disconnect axle shaft from transmission axle flange. - Remove nuts - arrows -. - Pull wheel bearing housing with ball joint out from control arm. - Pull drive axle out of wheel hub. Drive axle with Triple-roller joint AAR3300i (bolted), installing Remove any paint residue and/or corrosion on thread/splines of outer joint. - Install drive axle. - Insert outer joint as far as possible into spline in wheel hub.

10 Стр. 10 из 41 - Fasten ball joint to control arm - arrows -. Note: Check boot for damage or twisting. - Install inner joint of drive axle and initially tighten bolts diagonally to 10 Nm. - Tighten multi-point socket head bolts diagonally to torque specification listed. - Install lower sound insulation. Repair Manual, Body Exterior, Repair Group 50, Sound insulation - Assembly overview. - Tighten drive axle hex bolt. Note: The vehicle must not be sitting on its wheels, otherwise the wheel bearing can be damaged. - Install and fasten wheel 44-2, Torque specification for mounting wheels. Torque specifications Topic 40-3 Drive axle with CV joint VL100, assembly overview

11 Стр. 11 из 41 Outer constant velocity joint Replace only as a unit Removing 40-7, Pressing off outer constant velocity joint Installing: Using a plastic hammer, drive onto axle shaft as far as stop Checking 40-7, Outer constant velocity joint, checking Hex head bolt Torque specifications Topic 40-3

12 Стр. 12 из 41 Right axle shaft Clamp Tightening 40-7, Tighten clamp at smaller diameter Protective boot Check for tears and chafing Material: Hytrel (Polyelastomer) Clamp Tightening 40-7, Tightening hose clamp on outer joint Spring washer Installed location 40-7, Installed location of spring washer and thrust washer on outer joint Thrust washer Installed location 40-7, Installed location of spring washer and thrust washer on outer joint Circlip Insert in groove in shaft Constant velocity joint boots

13 Стр. 13 из 41 Material: Hytrel (Polyelastomer) No vent hole Check for tears and chafing Drive off constant velocity joint with a drift Before installing on constant velocity joint, coat sealing surface with D A2 Clamp Tightening 40-7, Tighten clamp at smaller diameter Left axle shaft Backing plate Multi-point socket head bolt Torque specification Topic 40-3 After disassembly, always replace bolts Circlip Remove and install using Circlip Pliers VW161A Gasket Adhesive surface on constant velocity joint must be free of oil and grease! Inner constant velocity joint Replace only as a unit Pressing off 40-7, Pressing off inner constant

14 Стр. 14 из 41 velocity joint Pressing on 40-7, Pressing on inner constant velocity joint Checking 40-7, Inner constant velocity joint, checking Spring washer Location 40-7, Installed location of spring washer on inner joint Disassembling Special tools, testers and auxiliary items required

15 Стр. 15 из 41 Thrust plate VW 401 Thrust plate VW 402 Punch VW 408 A Punch VW 411 Tube 37 mm Dia. VW 416B Thrust pad VW 447 H Special tools, testers and auxiliary items required Circlip pliers VW 161 A

16 Стр. 16 из 41 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 CV joint boot clamp tool V.A.G 1682 Assembly tool T Drive joint off axle shaft with a firm blow from a plastic hammer. Pressing off outer constant velocity joint - Press joint boot off from joint using a drift. For CV joint VL107 - Drive cover off of joint using a drift. Drive off cover for inner joint

17 Стр. 17 из 41 Continued for all CV joints - Remove circlip. - Remove both clamps, and push joint boot toward outer joint. Pressing off inner constant velocity joint Assembling - Slide small clamp for joint protective boot onto axle shaft. - Slide joint protective boot onto axle shaft. Installed location of spring washer on inner joint

18 Стр. 18 из 41 Spring washer Installed location of spring washer and thrust washer on outer joint Spring washer Thrust washer - Press on joint up to stop. - Insert circlip. Pressing on inner constant velocity joint Note: Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the axle shaft.

19 Стр. 19 из 41 Tightening hose clamp on outer joint - Install CV joint boot clamp tool V.A.G 1682 as shown in illustration. Make sure that the jaws of tension clamp seat in corners - arrows B - of hose clip. - Tighten hose clamp by turning spindle with a torque wrench (do not bend tensioning clamp). Note: The hard material of the joint boot (compared to rubber) makes it necessary to use a stainless steel hose clamp, it is only possible to tighten the hose clamp using CV joint boot clamp tool V.A.G Torque specification: 25 Nm Use torque wrench - C - with a range of 5 to 50 Nm (e.g. torque wrench V.A.G 1331 ). Make sure the spindle thread - A - is not tight. If necessary lubricate with MOS 2 grease. If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.

20 Стр. 20 из 41 Tighten clamp at smaller diameter Outer constant velocity joint, checking Joint must be disassembled to replace dirty grease or for checking the balls and ball tracks for wear and damage. Removing - Before disassembling mark ball hub position in relation to ball cage and housing with an electric scriber or oil stone. - Swivel ball hub and ball cage. - Remove balls one after another.

21 Стр. 21 из 41 - Turn cage until two rectangular windows - arrow - are aligned with joint housing. - Lift out cage together with hub. - Pivot segment of hub into rectangular cage opening. - Tilt hub out of cage. The 6 balls of each joint belong to one tolerance group. Check stub axle, hub, cage and balls for small indentations (pitting) and signs of seizure. Excessive backlash in joint will be noticed as a knock during load changes, in such cases joint must be replaced. Polished areas and ball track marks are not a reason for changing joint. Installing - Press half of total amount of grease 40 grams (1.4 oz.) into joint body. - Install cage with hub in joint housing. - Press in balls one after another from opposite sides whereby original position of hub to cage and joint housing must be restored. - Install new circlip in hub. - Distribute remaining grease in constant velocity joint boot. Inner constant velocity joint, checking Removing The joint must be disassembled to replace dirty grease or for checking balls and ball tracks for wear and damage.

22 Стр. 22 из 41 - Swivel ball hub and ball cage. - Press out ball joint housing in direction of - arrow-. - Press balls out of cage. Note: The ball hub and joint are paired. Must not be interchanged. - Tilt ball hub out of ball cage over ball track - arrow-. - Check joint housing, ball hub, ball cage and balls for indentations (pitting) and signs of seizure. Excessive backlash in joint will be noticed as a knock during load changes. In such cases joint must be replaced. Polished areas and ball track marks are not a reason for replacing joint. Installing

23 Стр. 23 из 41 - Insert ball hub over both chamfers into ball cage. The hub can be installed in any position. Press balls into cage. The ball hub has 2 different clearances between ball races, a larger one and a smaller one. - Insert hub with cage and balls upright into joint, thereby a smaller space - b - must face toward open side of joint. - Make sure that the chamfer of inner diameter of ball hub is visible after it is turned in.

24 Стр. 24 из 41 - Pivot in ball hub, while also pivoting hub out of cage - arrows - (as shown in the illustration). - Press cage firmly - arrow - until hub swings fully in position. Check operation of constant velocity joint: The constant velocity joint is correctly assembled when ball hub can be moved by hand backward and forward over its entire axial movement range. Drive axle constant velocity (CV) joint VL107, assembly overview

25 Стр. 25 из 41 Outer constant velocity joint Replace only as a unit Removing 40-7, Pressing off outer constant velocity joint Installing: Using a plastic hammer, drive onto axle shaft as far as stop Checking 40-7, Outer constant velocity joint, checking Hex head bolt Torque specifications Topic 40-3

26 Стр. 26 из 41 Circlip Insert in groove in axle shaft Thrust washer Installed location 40-7, Installed location of spring washer and thrust washer on outer joint Spring washer Installed location 40-7, Installed location of spring washer and thrust washer on outer joint Clamp Tightening 40-7, Tightening hose clamp on outer joint Protective boot Check for tears and chafing Material: Hytrel (Polyelastomer) Clamp Tightening 40-7, Tighten clamp at smaller diameter Axle shaft Clamp

27 Стр. 27 из 41 Tightening 40-7, Tighten clamp at smaller diameter Constant velocity joint boots Material: Hytrel (Polyelastomer) No vent hole Check for tears and chafing Drive off constant velocity joint with a drift Before installing on constant velocity joint, coat sealing surface with D A2 Clamp Backing plate Cover Carefully drive off with a drift Before installing on constant velocity joint, coat sealing surface with D A2 Adhesive surface must be free of oil and grease Inner constant velocity joint Replace only as a unit Pressing off 40-7, Pressing off inner constant velocity joint Pressing on 40-7, Pressing on inner constant velocity joint

28 Стр. 28 из 41 Checking 40-7, Inner constant velocity joint, checking Gasket Adhesive surface on constant velocity joint must be free of oil and grease! Circlip Remove and install with circlip pliers VW 161 A Cover Always replace Pressing off 40-7, Drive off cover for inner joint Multi-point socket head bolt Torque specifications 40-3 Topic After disassembly, always replace bolts Disassembling 40-7, Disassembling Assembling 40-7, Assembling Outer constant velocity joint, checking 40-7, Outer constant velocity joint, checking Inner constant velocity joint, checking 40-7, Inner constant velocity joint, checking

29 Стр. 29 из 41 Constant velocity (CV) joint function, checking 40-7, Check operation of constant velocity joint: Drive axle with Triple-roller joint AAR2600i, assembly overview Outer constant velocity joint Replace only as a unit Removing 40-7, Pressing off outer constant velocity joint Installing: Drive onto axle shaft with plastic hammer until securing ring engages. Checking 40-7, Outer constant velocity joint, checking

30 Стр. 30 из 41 Hex head bolt Torque specifications Topic 40-3 Right driveshaft Left axle shaft Clamp Tightening 40-7, Tighten clamp at smaller diameter Constant velocity joint boots Check for tears and chafing Material: Hytrel (Polyelastomer) Clamp Tightening 40-7, Tightening hose clamp on outer joint Spring washer Installed location 40-7, Installed location of spring washer and thrust washer on outer joint Thrust washer Installed location 40-7, Installed location of spring washer and thrust washer on outer joint

31 Стр. 31 из 41 Circlip Insert in groove in axle shaft Clamp Tension using hose clamp pliers V.A.G 1275 Triple-roller joint boot Check for tears and chafing Clamp Tension using hose clamp pliers V.A.G 1275 Circlip Joint piece Circlip Insert into groove in shaft using circlip pliers VW 161 A Triple-rotor star with rollers The chamfer - arrow - points to drive axle splines.

32 Стр. 32 из 41 Disassembling Servicing of outer joint can be found here 40-7, Disassembling. - Open both clamps on inner joint and slide back joint protective boot. - Pull joint off axle shaft. - Remove circlip. 1 - Pliers (commercially available) - or circlip pliers VW161A - Place axle shaft into press. - Press off triple roller star from axle shaft. - Pull protective boot off axle shaft. - Clean shaft, joint and groove for oil seal.

33 Стр. 33 из 41 Assembling - Slide small clamp for joint protective boot onto axle shaft. - Slide joint protective boot onto axle shaft. - Slide joint onto axle shaft. Assembling triple-roller star Conical-type axle shaft The chamfer on triple-roller star faces toward shaft, this is used as an assembly aid. - Install triple-roller star onto axle shaft and press onto stop. - Make sure that the pressure does not exceed 3.0 t! - If necessary coat axle shaft splines and triple-roller star with lubricating paste G A2.. - Insert circlip, make sure seated correctly. As of , a different grease has been introduced for triple-roller joint. This grease is not compatible with that which was previously used. Therefore, the triple-roller joint must be cleaned of all grease when servicing. - Press 70 grams of joint grease from repair set, into triple roller joint. - Slide joint over rollers and hold. - Press 60 grams of joint grease, from repair kit, into reverse side of triple-roller joint.

34 Стр. 34 из 41 - Install joint protective boot. Assembling triple-roller star Cylindrical-type axle shaft - Install triple roller-star onto axle shaft and press onto stop. - Make sure that the pressure does not exceed 3.0 t! - If necessary coat axle shaft splines and triple-roller star with lubricating paste G A2.. - Insert circlip, make sure seated correctly. - Press 70 grams of joint grease from repair kit, into tripleroller joint. - Slide joint over rollers and hold. - Press 60 grams of joint grease, from repair kit, into reverse side of triple roller joint. - Install joint protective boot. - Tension both clamps with hose clamp pliers V.A.G Drive axle with Triple-roller joint AAR3300i, assembly overview

35 Стр. 35 из 41 Outer constant velocity joint Replace only as a unit Removing 40-7, Pressing off outer constant velocity joint Installing: Drive onto axle shaft with plastic hammer until securing ring engages. Checking 40-7, Outer constant velocity joint, checking Hex head bolt Torque specifications Topic 40-3

36 Стр. 36 из 41 Circlip Insert in groove in axle shaft Thrust washer Location 40-7, Installed location of spring washer and thrust washer on outer joint Spring washer Location 40-7, Installed location of spring washer and thrust washer on outer joint Clamp Tightening 40-7, Tightening hose clamp on outer joint Constant velocity joint boots Check for tears and chafing Material: Hytrel (Polyelastomer) Clamp Tightening 40-7, Tighten clamp at smaller diameter Axle shaft Clamp

37 Стр. 37 из 41 Tension with hose clamp pliers V.A.G 1275 Triple-roller joint boot Check for tears and chafing Clamp Tension using hose clamp pliers V.A.G 1275 Triple-rotor star with rollers The chamfer - arrow - points to axle shaft splines. Circlip Insert in groove in axle shaft Joint piece For automatic transmission Circlip Multi-point socket head bolt Torque specifications Topic 40-3 Joint piece Disassembling

38 Стр. 38 из 41 Servicing of outer joint can be found 40-7, Disassembling. - Open both clamps on inner joint and slide back joint protective boot. - Pull joint off axle shaft. - Remove circlip. 1 - Pliers (commercially available) - or circlip pliers VW161A - Place axle shaft into press. - Press off triple-roller star from axle shaft. - Pull protective boot off axle shaft. - Clean shaft, joint and groove for oil seal. Assembling

39 Стр. 39 из 41 - Slide small clamp for joint protective boot onto axle shaft. - Slide joint protective boot onto axle shaft. - Slide joint onto axle shaft. Assembling triple-roller star Conical-type axle shaft The chamfer on triple-roller star faces toward axle shaft, this is used as an assembly aid. - Install triple-roller star onto shaft and press onto stop. - Make sure that the pressure does not exceed 3.0 t! - If necessary coat axle shaft splines and triple-roller star with lubricating paste G A2. - Insert circlip, make sure seated correctly. - Press 70 grams of joint grease from repair kit, into tripleroller joint. - Slide joint over rollers and hold. - Press 60 grams of joint grease, from repair kit, into reverse side of triple-roller joint. - Install joint protective boot. Assembling triple-roller star Cylindrical-type axle shaft

40 Стр. 40 из 41 - Install triple-roller star onto axle shaft and press onto stop. - Make sure that the pressure does not exceed 3.0 t! - If necessary coat axle shaft splines and triple-roller star with lubricating paste G A2.. - Insert circlip, make sure seated correctly. - Press 70 grams of joint grease from repair kit, into triple roller joint. - Slide joint over rollers and hold. - Press 60 grams of joint grease, from repair kit, into reverse side of triple roller joint. - Install joint protective boot. - Install clamp. Note:

41 Стр. 41 из 41 For a better alignment of the multi-point socket head bolts when mounting the axle shaft, it is necessary that the clamping ear of the clamp - arrow A - is placed between the fixing flanges from the joint - arrow B -. - Tension clamp using hose clamp pliers VAG Tension small clamp using hose clamp pliers VAG1275.

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