Boot, Replacing

Special tools and workshop equipment required 

• Flanging Tool:T40261 
  Fig 1: Identifying Flanging Tool T40261

  Courtesy of AUDI
• Hose Clamp:23 to 35 mm Diameter 

Procedure

Fig 2: Identifying Special Tool T40261/1

Courtesy of AUDI

-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

-- Clamp the driveshaft with the Flanging Tool - Protective Jaws :T40261/1  into the vise, as shown.

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

Fig 3: Removing Metal Sleeve Flanging

Courtesy of AUDI

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

-- Using a side cutter, open the remaining flange -arrow- of the metal sleeve.

Fig 4: Removing Metal Sleeve Flanging With Side Cutter

Courtesy of AUDI

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

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

Fig 5: Removing Support Ring

Courtesy of AUDI

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

-- Remove the excess old grease.

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

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

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

Fig 6: Checking Sealing Surface

Courtesy of AUDI

-- If grooves are created when removing the old boot, flatten them.

-- Place the new O-ring -1- in the groove.

-- Push the support ring -2- in the opening of the boot -1-.

Fig 7: Identifying Support Ring

Courtesy of AUDI

• Installation direction: the recess -arrow A- is pushed in the boot.
• The guides -arrow B- for the support ring must be visible on the edge of the opening of the boot.

-- Fold up the boot -2- inward in the metal sleeve -1-.

Fig 8: Identifying Hose Clamp

Courtesy of AUDI

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

• The end of the support ring must be free.

-- Remove the hose clamp -2- until the guides -1- of the support ring can be inserted in the groove -3- of the inner section of the joint.

Fig 9: Installing Support Ring Guides

Courtesy of AUDI

-- Loosen the hose clamp -2- and remove.

• The guides for the support ring must engage in the groove of the inner section -arrow-.

-- Push the metal sleeve of the boot all the way on 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 10: Identifying Special Tool T40261

Courtesy of AUDI

-- Flange the metal sleeve by turning the Flanging Tool:T40261  back and forth.

• The twist angle must be minimum 90° while 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.