Replacing drive shaft bellows

Before disassembly, mark the correct position of the bellows for reinstallation -arrow-  .

Information 

• Do not remove bellows holder on the joint on the wheel side  .
• Replacing constant-velocity joints: Only the constant-velocity joint on the transmission side is available. Otherwise, replace the complete drive shaft  .
  Fig 2: Locating Bellows Marking Position On Drive Shaft

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1. 2.1. Remove clamps (clips) -1-  .
   Fig 3: Identifying Constant-Velocity Joint On Transmission Side

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2. 2.2. Then force off the cover -3-  and bellows holder -4-  evenly using a suitable mandrel.
3. 2.3. Move bellows and bellows holder to the wheel side of the drive shaft.
4. 2.4. Remove circlip -1-  using suitable pliers.
   Fig 4: Identifying Circlip

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5. 2.5. Press off constant-velocity joint using -1- press tool VW 408 A  and -2- pressure plate VW 401  .
   Fig 5: Pressing Constant-Velocity Joint

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6. 2.6. Slide bellows and bellows holder off the drive shaft.

Fig 6: Identifying Bellows On Wheel Side

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1. 3.1. Remove clamps (clips) -1 and 3-  .
2. 3.2. Slide bellows -2-  off the drive shaft.

   Information 

   Do not remove bellows holder on the joint on the wheel side.

   The constant-velocity joints must be able to move slightly in an axial direction (length compensation).

Fit large clamp (clip) -1-  and tighten using pliers Nr.74  or commercially available special pliers.

Slide small clamp (clip) -3-  onto the drive shaft, but do not tighten yet.

Fig 8: Identifying Bellows On Wheel Side And Clamp

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1. 8.1. Coat sealing face of the bellows holder -arrow-  with special sealant .
   Fig 9: Locating Transmission Side Bellows Holder Sealant

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2. 8.2. Tap bellows holder evenly onto the constant-velocity joint at congruent holes (holes for the fastening screws) using a plastic hammer (do not use force).

   Tap on bellows holder on the side of the constant-velocity joint with the groove -arrow-  .

   Fig 10: Fitting Bellows Holder On Constant-Velocity Joint

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Fig 11: Pressing On Constant-Velocity Joint

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1. 9.1. Tap or press the constant-velocity joint -1-  using a suitable pressure piece -3-  so that it fits onto the profile shaft -2-  at the correct position.
2. 9.2. Fit new circlip using suitable pliers.

1. 10.1. Coat sealing face of the cover -arrow-  with special sealant .
   Fig 12: Locating Cover Sealant

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2. 10.2. Tap cover evenly onto the constant-velocity joint at congruent holes (holes for the fastening screws) using a plastic hammer (do not use force).