Preliminary Work

Remove drive shaft.

> 422119 REMOVING AND INSTALLING DRIVE SHAFT  - portion on "Removing"

Replacing drive shaft bellows 

Fig 1: Drive Shaft Exploded View

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Drive shaft disassembled

1. Clamp (clip), small
2. Clamp (clip), large
3. Cap
4. Bellows holder
5. Circlip
6. Constant-velocity joint
7. Bellows
8. Clamp (clip), small
9. Clamp (clip), large
10. Bellows
11. Profile shaft

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. 

1. Mark the drive shaft (position of bellows).

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

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   Marking position of bellows on drive shaft

2. Remove bellows (on transmission side).
   1. 2.1  Remove clamps (clips) -1-  .

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      Constant-velocity joint on transmission side

   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.

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      Removing circlip

   5. 2.5  Press off constant-velocity joint using -1-  > VW408A - Pressure pad  and -2-  > VW401 - Pressure plate  .

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      Pressing off constant-velocity joint

   6. 2.6  Slide bellows and bellows holder off the drive shaft.
3. Remove bellows on wheel side.

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   Bellows on wheel side

   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).

4. Re-grease constant-velocity joint on the wheel side using special grease if necessary (see Parts Catalogue). Grease must be pressed in through the bellows holder into the joint.

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   Greasing constant-velocity joint on wheel side

5. Fit bellows -2-  on the wheel side on the bellows holder.

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   Bellows on wheel side

   Fit large clamp (clip) -1-  and tighten using > V.A.G 1275A - Hose clip pliers  or commercially available special pliers.

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

6. Re-grease constant-velocity joint on the transmission Side using special grease if necessary (see parts catalogue).
7. Slide clamps for bellows onto the profile shaft.
8. Assemble bellows with bellows holder.
   1. 8.1  Coat sealing face of the bellows holder -arrow-  with special sealant (see parts catalogue).

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      Coating bellows holder on transmission side with sealant

   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-  .

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      Fitting bellows holder on constant-velocity joint (shown as an example)

9. Assemble constant-velocity joint and bellows -1-  with the profile shaft -2-  .

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   Pressing on constant-velocity joint

   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.
10. Install cover on the transmission side.
    1. 10.1  Coat sealing face of the cover -arrow-  with special sealant (see parts catalogue).

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       Coating cover with sealant

    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).
11. Position bellows according to the marking applied previously -arrow-  . Tighten clamps (clips) at this position using > V.A.G 1275A - Hose clip pliers  or commercially available special pliers.

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    Marking position of bellows on drive shaft