Disassembling Drive Shaft - Transmission Side

Information 

• The bellows on the wheel-side joint cannot be replaced. 
• Only the constant-velocity joint on the transmission side, bellows and cap are available. 
• The bellows with bellows holder and large clamp are one spare part. 
• If the wheel side is damaged, replace the entire drive shaft. 

Information 

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

Information 

Always replace circlip after removal.

Component overview:

Fig 1: Rear Drive Shaft Components Location

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Individual rear drive shaft parts

Clean drive shaft.

2. Mark drive shaft (position of bellows).

   Before disassembling, mark the correct position of the inner bellows for re-installation -Arrow-  .

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   Marking position of bellows on drive shaft

3. Remove bellows -4-  with bellows holder -3-  on transmission side.

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   Constant-velocity joint on transmission side

   1. 3.1  Remove small clamp -1-  and replace.
   2. 3.2  Carefully pry off cover -2-  and bellows holder -3-  evenly using an aluminum or plastic mandrel.
   3. 3.3  Move bellows together with bellows holder -1-  onto the wheel-side profile shaft.

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      Bellows with sleeve and clamp

4. Remove circlip -1-  using > VAS 6943 - circlip pliers  (or similar).

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   Removing circlip

   1. 4.1 Replace circlip.
5. Remove old lubricant from the joint, bellows and profile shaft as far as possible.

   If the constant-velocity joint is replaced, clean the profile shaft and splines carefully.

6. Press off constant-velocity joint using > VW408A - press tool-1-  and > VW401 - thrust plate -2-  .

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   pressing off constant-velocity joint

7. Push bellows and bellows holder from the profile shaft and clean the profile shaft.
8. Grease both sides of constant-velocity joint on transmission side -Symbol-  using special grease (see Parts Information).

   Sealing surfaces for cap and bellows holder must be free of grease.

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   Greasing constant-velocity joint

9. Push new (small) clamp for bellows onto the profile shaft.
10. Assemble new bellows with bellows holder and constant-velocity joint.
    1. 10.1  Coat sealing face of the bellows holder -Arrow-  using special sealant (see Parts Information) as shown.

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       Applying sealant to bellows holder on transmission side

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

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

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       Position of bellows holder in relation to groove on constant-velocity joint

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

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    Pressing on constant-velocity joint

    1. 11.1  Carefully slide the bellows over the splines and into the profile shaft.
    2. 11.2  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.
    3. 11.3  Fit new circlip using > VAS 6943 - circlip pliers  (or similar).
12. Install cover on transmission side.
    1. 12.1  Coat sealing face of cap -Arrow-  using special sealant (see Parts Information) as shown.

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       Applying sealant to cap

    2. 12.2  Tap cover evenly onto the constant-velocity joint at congruent holes (holes for the screws) using a plastic hammer (do not use force).
13. Position bellows according to the marking applied previously -Arrow-  . Close new clamp using > V.A.G 1275A - hose clip pliers  or commercially available special pliers.

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    Marking position of bellows on drive shaft