Boot, Replacing, Driveshaft Connected On Transmission Side

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Special tools and workshop equipment required

Flanging Tool T40261
Hose Clamp 23 to 35 mm Diameter

Procedure

Fig 1: Identifying Special Tool T40261/1

Courtesy of AUDI OF AMERICA, LLC

-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING, DRIVESHAFT CONNECTED ON TRANSMISSION SIDE .

-- Clamp the driveshaft with the Flanging Tool - 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 in direction of -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 in direction of -arrows- and remove the boot with the metal sleeve.

Fig 4: Removing Support Ring

Courtesy of AUDI OF AMERICA, LLC

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.

NOTE:

Fill with the same amount of grease, that has been clean off plus the amount that remains in the old boot.

-- 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

Courtesy of AUDI OF AMERICA, LLC

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

Courtesy of AUDI OF AMERICA, LLC

-- 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 -2- and remove.

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

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

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

Fig 9: Identifying Special Tool T40261

Courtesy of AUDI OF AMERICA, LLC

-- Flange the metal sleeve by turning the Flanging Tool 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 Flanging Tool T40261.
The flanging is finished when the hand wheel for the Flanging Tool T40261 can only be turned if a lot of force is used.