Driveshaft Boot Inserted On Transmission Side

Special tools and workshop equipment required 

• Flanging Tool T40261

Procedure 

Fig 1: Identifying Special Tool T40261/1

Courtesy of AUDI OF AMERICA, LLC

-- Remove the driveshaft, refer to DRIVESHAFT, MOUNTED ON TRANSMISSION SIDE .

-- 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

Courtesy of AUDI OF AMERICA, LLC

• The surface on the driveshaft joint must not be damaged.

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

Fig 3: Removing Metal Sleeve Flanging With Side Cutter

Courtesy of AUDI OF AMERICA, LLC

-- 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

Courtesy of AUDI OF AMERICA, LLC

-- 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

Courtesy of AUDI OF AMERICA, LLC

-- 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.

• The end of the support ring must be freed up.

-- 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

Courtesy of AUDI OF AMERICA, LLC

-- Loosen the hose clamp and remove it.

• The support ring guides must catch on the inside of the groove -arrow-.

-- 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.