Driveshaft Boot Inserted On Transmission Side

Special tools and workshop equipment required

Procedure

Fig 1: Identifying Special Tool T40261/1

Courtesy of AUDI OF AMERICA, LLC

-- Clamp the driveshaft with the protective jaws T40261/1 into the vise, as shown in the illustration.

-- Carefully loosen the metal sleeve flanging -1- from the driveshaft joint at one place with a screwdriver.

Fig 2: Removing Metal Sleeve Flanging

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-- Open the rest of the metal sleeve flanging -arrow- with a side cutter.

Fig 3: Removing Metal Sleeve Flanging With Side Cutter

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-- Remove the old boot with the metal sleeve from the driveshaft joint.

-- Break the support ring with the water pump pliers -arrows- and remove the boot with the metal sleeve.

Fig 4: Removing Support Ring

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NOTE:

The inside of the joint and the balls remain in the driveshaft joint.

-- Wipe away any excess grease.

-- Grease the driveshaft joint with grease from the installation kit.

-- Clean the sealing surface -arrow- on the driveshaft joint -2-.

Fig 5: Checking Sealing Surface

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-- If there are scratches left behind after removing the old boot, smooth them out.

-- Insert a new O-ring -1- in the groove.

-- Install the support ring -2- in the boot opening -1-.

Fig 6: Identifying Support Ring

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Direction of installation: the depression -arrow A- is slid into the boot.
The guides for the support ring -arrow B- must be visible on the edge of the boot opening.

-- Fold the boot -2- inward inside the metal sleeve -1-.

Fig 7: Identifying Hose Clamp

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-- Slide the hose clamp -arrow- onto the open guides for the support ring -3- as shown in the illustration.

-- Tighten the hose clamp -2- until the support ring guides -1- are able to be inserted into the groove -3- of the inside of the joint.

Fig 8: Installing Support Ring Guides

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-- Loosen the hose clamp and remove it.

-- Slide the metal sleeve for the boot all the way onto the joint.

-- Attach the T40261 to the metal sleeve so that the guide tube stops -arrow- are touching the edge of the metal sleeve.

Fig 9: Identifying Special Tool T40261

Courtesy of AUDI OF AMERICA, LLC

-- Unflange the metal sleeve by turning the T40261 back and forth.

The turning angle must be at least 90° when turning it back and forth.
While turning it back and forth, turn the hand wheel for the fT40261.
The flanging is finished when the hand wheel for the T40261 can only be turned if a lot of force is used.