Aandrijfassen

Volkswagen Passat B6 - Drive shaft, servicing Стр.
1 из 41
40 - 7
Drive shaft, servicing

Drive shafts, overview
I - Assembly overview: Drive axle with

CV joint VL100 40-7, Drive axle with
CV joint VL100, assembly overview
II - Assembly overview: Drive axle

with CV joint VL107 40-7, Drive axle
constant velocity (CV) joint VL107,
assembly overview
III - Assembly overview: Drive axle

with Triple-roller joint AAR2600i 40-
7, Drive axle with Triple-roller joint
AAR2600i, assembly overview
IV - Assembly overview: Drive axle

with Triple-roller joint AAR3300i 40-
Drive shaft, servicing Стр. 2 из 41
7, Drive axle with Triple-roller joint

AAR3300i, assembly overview
Difference of drive axles in installed condition
VL100 VL107 AAR2600i AAR3300i

Diameter of inner joint in mm 100 107 - -
Cover between inner joint and flange shaft - X - -
Inner joint inserted into the transmission (only
- - X X
automatic transmission)
Inner joint fastened to flange shaft of transmission
(only manual transmission and direct-shift X X - X
transmission)
Fastening drive axle bolt, loosening and tightening
Special tools, testers and auxiliary items required
Angle wrench V.A.G 1756
The wheel bearings must not be loaded when drive axle

fastener on wheel side is loose.
If bearings are loaded by vehicles own weight the wheel

bearing will be damaged. The wheel bearings will be
stressed and life expectancy reduced. Therefore, observe
the following:
Procedure for loosening bolt.
Vehicles without drive axle must not be moved, otherwise

wheel bearing will be damaged. If vehicle must be moved,
observe the following:
- Instead of drive axle, install an outer joint.

- Tighten outer joint to 120 Nm.
Loosen hex bolt.
- With vehicle sitting on its wheels, loosen bolt up to 90 ,

otherwise wheel bearing will be damaged.
- Lift vehicle until wheels hang freely.
- Apply brake (second technician required).
- Remove bolt - arrow - .
Tighten hex bolt.
- Replace bolt
Note:
To tighten the drive axle, the wheels must still not

touch the floor; otherwise the wheel bearing can be
damaged.
- Apply brake (second technician required).
- Tighten bolt to 200 Nm.
- Lower vehicle onto its wheels.
- Turn bolt an additional 180 .
Drive axle, removing and installing
Special tools, testers and auxiliary items required

Torque wrench V.A.G 1332
Angle wrench V.A.G 1756
Caution!
When disassembling and performing repairs on

vehicle, the drive axles must not be allowed to hang
down and contact the stops in the joint by overflexing.
Drive axle with constant velocity (CV) joint, removing
- Loosen drive axle hex bolt 40-7, Fastening drive axle

bolt, loosening and tightening .
Note:
The vehicle must not be sitting on its wheels,

otherwise the wheel bearing can be damaged.
- Remove lower sound insulation
Repair Manual, Body Exterior, Repair Group 50, Sound

insulation - Assembly overview
- Disconnect axle shaft from transmission axle flange.
- Remove wheel.
- Push outer joint out of wheel hub by hand.
- Remove nuts - arrows - .
- Pull wheel bearing housing with ball joint out from control
arm.
- Pull drive axle out of wheel hub.
Drive axle with constant velocity (CV) joint, installing
Remove any paint residue and/or corrosion on

thread/splines of outer joint.
- Install drive axle.
- Insert outer joint as far as possible into spline in wheel

hub.
- Fasten ball joint to control arm - arrows - .
Note:
Check boot for damage or twisting.

- Install inner joint of drive axle and initially tighten bolts

diagonally to 10 Nm.
- Tighten multi-point socket head bolts diagonally to torque

specification listed.
- Install lower sound insulation

- Tighten drive axle hex bolt.
Note:

- Install and fasten wheel 44-2, Torque specification for

mounting wheels .
Torque specifications 40-3, Front axle, torque

specifications
Drive axle with Triple-roller joint AAR2600i and AAR3300i

(mated), removing

- Remove wheel.

.
arm.
- Pull drive axle out from wheel hub and secure it to body.
- Place wedge tool T10161 between transmission housing

and triple-roller joint.
- By hitting wedge tool T10161 with a hammer, press inner

joint out of transmission.
- Remove drive axle.
Drive axle with Triple-roller joint AAR2600i and AAR3300i

(mated), installing
- Install new circlip into groove of joint shank.
- Engage outer and inner splines of joint and transmission.
- Grab drive axle by hand and push it into joint up to stop.
- Now push joint into transmission with a "jolt" .
The sliding part in joint can be used for this "jolt" . When
doing this, do not pull drive axle too far out of joint.
Note:
Do not use a hammer or other impact tool under any

circumstances!
- Verify that the drive axle is securely seated in

transmission, by pulling joint against resistance of circlip.
For this check, do not pull on drive axle, but rather

only on joint.

hub.
- Install lower sound insulation
Repair Manual, Body Exterior, Repair Group 50, sound

Note:
Note:


mounting wheels .
Torque specifications 40-3, Front axle, torque

specifications
Drive axle with Triple-roller joint AAR3300i (bolted), removing

- Remove wheel.

- Disconnect axle shaft from transmission axle flange.
arm.
- Pull drive axle out of wheel hub.
Drive axle with Triple-roller joint AAR3300i (bolted), installing
Remove any paint residue and/or corrosion on

thread/splines of outer joint.
- Install drive axle.

hub.
Note:
- Install inner joint of drive axle and initially tighten bolts

diagonally to 10 Nm.
- Tighten multi-point socket head bolts diagonally to torque

specification listed.
- Install lower sound insulation.

Note:


mounting wheels .
Torque specifications Topic 40-3
Drive axle with CV joint VL100, assembly overview

Outer constant velocity joint
Replace only as a unit
Removing 40-7, Pressing

off outer constant velocity
joint
Installing: Using a plastic

hammer, drive onto axle
shaft as far as stop
Checking 40-7, Outer

constant velocity joint,
checking
Hex head bolt
Torque specifications
Topic 40-3
Replace each time it is

removed
Right axle shaft
Clamp

removed
Tightening 40-7, Tighten

clamp at smaller diameter
Protective boot
Check for tears and chafing
Material: Hytrel
(Polyelastomer)
Clamp

removed
Tightening 40-7,
Tightening hose clamp on
outer joint
Spring washer
Installed location 40-7,

Installed location of spring
washer and thrust washer on
outer joint
Thrust washer

outer joint
Circlip

removed
Insert in groove in shaft
Constant velocity joint boots

Material: Hytrel
(Polyelastomer)
No vent hole
Drive off constant velocity

joint with a drift
Before installing on constant

velocity joint, coat sealing
surface with D 454 300 A2
Clamp

removed

Left axle shaft
Backing plate
Multi-point socket head bolt
Torque specification Topic

40-3
After disassembly, always

replace bolts
Circlip
Remove and install using

Circlip Pliers VW161A
Gasket
Adhesive surface on
constant velocity joint must
be free of oil and grease!
Inner constant velocity joint
Pressing off 40-7,

Pressing off inner constant
velocity joint
Pressing on 40-7,
Pressing on inner constant
velocity joint
Checking 40-7, Inner

checking
Spring washer
Location 40-7, Installed

location of spring washer on
inner joint
Disassembling
Special tools, testers and auxiliary items

required
Thrust plate VW 401
Thrust plate VW 402
Punch VW 408 A
Punch VW 411
Tube 37 mm Dia. VW 416B
Thrust pad VW 447 H
Special tools, testers and auxiliary items

required
Circlip pliers VW 161 A

CV joint boot clamp tool V.A.G

1682
Assembly tool T10065
- Drive joint off axle shaft with a firm blow from a plastic
hammer.
Pressing off outer constant velocity joint
- Press joint boot off from joint using a drift.
For CV joint VL107
- Drive cover off of joint using a drift.
Drive off cover for inner joint

Continued for all CV joints
- Remove circlip.
- Remove both clamps, and push joint boot toward outer

joint.
Pressing off inner constant velocity joint
Assembling
- Slide small clamp for joint protective boot onto axle shaft.
- Slide joint protective boot onto axle shaft.
Installed location of spring washer on inner joint

Spring washer
Installed location of spring washer and thrust washer on

outer joint
Spring washer
Thrust washer
- Press on joint up to stop.
- Insert circlip.
Pressing on inner constant velocity joint
Note:
Chamfer on inner diameter of ball hub (splines) must

face the contact shoulder on the axle shaft.
Tightening hose clamp on outer joint
- Install CV joint boot clamp tool V.A.G 1682 as shown in

illustration. Make sure that the jaws of tension clamp seat
in corners - arrows B - of hose clip.
- Tighten hose clamp by turning spindle with a torque

wrench (do not bend tensioning clamp).
Note:
The hard material of the joint boot (compared to

rubber) makes it necessary to use a stainless steel
hose clamp, it is only possible to tighten the hose
clamp using CV joint boot clamp tool V.A.G 1682 .
Torque specification: 25 Nm
Use torque wrench - C - with a range of 5 to 50 Nm

(e.g. torque wrench V.A.G 1331 ).
Make sure the spindle thread - A - is not tight. If

necessary lubricate with MOS 2 grease.
If the thread is tight e.g. dirty, the required tensioning

force for the hose clamp will not be achieved in spite
of correct torque specification settings.
Tighten clamp at smaller diameter
Outer constant velocity joint, checking
Joint must be disassembled to replace dirty grease or for

checking the balls and ball tracks for wear and damage.
Removing
- Before disassembling mark ball hub position in relation to

ball cage and housing with an electric scriber or oil stone.
- Swivel ball hub and ball cage.
- Remove balls one after another.

- Turn cage until two rectangular windows - arrow - are

aligned with joint housing.
- Lift out cage together with hub.
- Pivot segment of hub into rectangular cage opening.
- Tilt hub out of cage.
The 6 balls of each joint belong to one tolerance group.

Check stub axle, hub, cage and balls for small indentations
(pitting) and signs of seizure. Excessive backlash in joint
will be noticed as a knock during load changes, in such
cases joint must be replaced. Polished areas and ball track
marks are not a reason for changing joint.
Installing
- Press half of total amount of grease 40 grams (1.4 oz.)

into joint body.
- Install cage with hub in joint housing.
- Press in balls one after another from opposite sides

whereby original position of hub to cage and joint housing
must be restored.
- Install new circlip in hub.
- Distribute remaining grease in constant velocity joint

boot.
Inner constant velocity joint, checking
Removing
The joint must be disassembled to replace dirty grease or

for checking balls and ball tracks for wear and damage.
- Swivel ball hub and ball cage.
- Press out ball joint housing in direction of - arrow - .
- Press balls out of cage.
Note:
The ball hub and joint are paired. Must not be

interchanged.
- Tilt ball hub out of ball cage over ball track - arrow - .
- Check joint housing, ball hub, ball cage and balls for
indentations (pitting) and signs of seizure.
Excessive backlash in joint will be noticed as a knock

during load changes. In such cases joint must be replaced.
Polished areas and ball track marks are not a reason for
replacing joint.
Installing
- Insert ball hub over both chamfers into ball cage. The
hub can be installed in any position. Press balls into cage.
The ball hub has 2 different clearances between ball races,

a larger one and a smaller one.
- Insert hub with cage and balls upright into joint, thereby a
smaller space - b - must face toward open side of joint.
- Make sure that the chamfer of inner diameter of ball hub

is visible after it is turned in.
- Pivot in ball hub, while also pivoting hub out of cage -

arrows - (as shown in the illustration).
- Press cage firmly - arrow - until hub swings fully in

position.
Check operation of constant velocity joint:
The constant velocity joint is correctly assembled when ball

hub can be moved by hand backward and forward over its
entire axial movement range.
Drive axle constant velocity (CV) joint VL107, assembly

overview

joint
Installing: Using a plastic

hammer, drive onto axle
shaft as far as stop

checking
Hex head bolt
Topic 40-3

removed
Circlip

removed
Insert in groove in axle shaft
Thrust washer

outer joint
Spring washer

outer joint
Clamp

removed
Tightening 40-7,
outer joint
Protective boot
Material: Hytrel
(Polyelastomer)
Clamp

removed

Axle shaft
Clamp

removed

Material: Hytrel
(Polyelastomer)
No vent hole
Drive off constant velocity

joint with a drift

Clamp

removed
Backing plate
Cover
Carefully drive off with a

drift

Adhesive surface must be

free of oil and grease
Inner constant velocity joint
Pressing off 40-7,

Pressing off inner constant
velocity joint
Pressing on 40-7,
Pressing on inner constant
velocity joint
Checking 40-7, Inner

checking
Gasket
Adhesive surface on
constant velocity joint must
be free of oil and grease!
Circlip
Remove and install with

circlip pliers VW 161 A
Cover

removed
Always replace
Pressing off 40-7, Drive

off cover for inner joint
Torque specifications Topic

40-3
After disassembly, always

replace bolts
Disassembling
40-7, Disassembling
Assembling
40-7, Assembling
Outer constant velocity joint, checking
40-7, Outer constant velocity joint, checking
Inner constant velocity joint, checking
40-7, Inner constant velocity joint, checking

Constant velocity (CV) joint function, checking
40-7, Check operation of constant velocity joint:
Drive axle with Triple-roller joint AAR2600i, assembly

overview

joint
Installing: Drive onto axle

shaft with plastic hammer
until securing ring engages.

checking
Hex head bolt
Topic 40-3

removed
Right driveshaft
Left axle shaft
Clamp

removed

Material: Hytrel
(Polyelastomer)
Clamp

removed
Tightening 40-7,
outer joint
Spring washer

outer joint
Thrust washer

outer joint
Circlip

removed
Clamp

removed
Tension using hose clamp

pliers V.A.G 1275
Triple-roller joint boot
Clamp

removed

pliers V.A.G 1275
Circlip

removed
Joint piece
Circlip

removed
Insert into groove in shaft

using circlip pliers VW 161
A
Triple-rotor star with rollers
The chamfer - arrow - points to

drive axle splines.
Disassembling
Servicing of outer joint can be found here 40-7,

Disassembling .
- Open both clamps on inner joint and slide back joint

protective boot.
- Pull joint off axle shaft.
- Remove circlip.
1 - Pliers (commercially available)

- or circlip pliers VW161A
- Place axle shaft into press.
- Press off triple roller star from axle shaft.
- Pull protective boot off axle shaft.
- Clean shaft, joint and groove for oil seal.

Assembling
- Slide joint onto axle shaft.
Assembling triple-roller star
Conical-type axle shaft
The chamfer on triple-roller star faces toward shaft, this is

used as an assembly aid.
- Install triple-roller star onto axle shaft and press onto

stop.
- Make sure that the pressure does not exceed 3.0 t!
- If necessary coat axle shaft splines and triple-roller star

with lubricating paste G 052 142 A2 ..
- Insert circlip, make sure seated correctly.
As of 08.2004, a different grease has been introduced for

triple-roller joint. This grease is not compatible with that
which was previously used. Therefore, the triple-roller joint
must be cleaned of all grease when servicing.
- Press 70 grams of joint grease from repair set, into triple

roller joint.
- Slide joint over rollers and hold.
- Press 60 grams of joint grease, from repair kit, into

reverse side of triple-roller joint.
- Install joint protective boot.
Cylindrical-type axle shaft
- Install triple roller-star onto axle shaft and press onto

stop.

- Press 70 grams of joint grease from repair kit, into triple-

roller joint.

reverse side of triple roller joint.
- Tension both clamps with hose clamp pliers V.A.G

1275 .
Drive axle with Triple-roller joint AAR3300i, assembly

overview

joint
Installing: Drive onto axle

shaft with plastic hammer
until securing ring engages.

checking
Hex head bolt
Topic 40-3

removed
Circlip

removed
Thrust washer

location of spring washer
and thrust washer on outer
joint
Spring washer

location of spring washer
and thrust washer on outer
joint
Clamp

removed
Tightening 40-7,
outer joint
Material: Hytrel
(Polyelastomer)
Clamp

removed

Axle shaft
Clamp

removed
Tension with hose clamp

pliers V.A.G 1275
Triple-roller joint boot
Clamp

removed

pliers V.A.G 1275
Triple-rotor star with rollers
The chamfer - arrow - points to

axle shaft splines.
Circlip

removed
Joint piece
For automatic transmission
Circlip

removed
Topic 40-3
Joint piece
Disassembling
Servicing of outer joint can be found 40-7,

Disassembling .
- Open both clamps on inner joint and slide back joint

protective boot.
- Pull joint off axle shaft.
- Remove circlip.
1 - Pliers (commercially available)

- or circlip pliers VW161A
- Place axle shaft into press.
- Press off triple-roller star from axle shaft.
- Pull protective boot off axle shaft.
- Clean shaft, joint and groove for oil seal.
Assembling
- Slide joint onto axle shaft.
Conical-type axle shaft
The chamfer on triple-roller star faces toward axle shaft,

this is used as an assembly aid.
- Install triple-roller star onto shaft and press onto stop.

with lubricating paste G 052 142 A2.
- Press 70 grams of joint grease from repair kit, into triple-

roller joint.

reverse side of triple-roller joint.
Cylindrical-type axle shaft

- Install triple-roller star onto axle shaft and press onto

stop.

- Press 70 grams of joint grease from repair kit, into triple

roller joint.

reverse side of triple roller joint.
- Install clamp.
Note:
For a better alignment of the multi-point socket head

bolts when mounting the axle shaft, it is necessary
that the clamping ear of the clamp - arrow A - is
placed between the fixing flanges from the joint -
arrow B - .
- Tension clamp using hose clamp pliers VAG1275 .
- Tension small clamp using hose clamp pliers

VAG1275 .

Aandrijfassen

Enviado por

Dados do documento

Descrição original:

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Aandrijfassen

Enviado por

Direitos autorais:

Formatos disponíveis

Volkswagen Passat B6 - Drive shaft, servicing Стр.

Drive shaft, servicing

I - Assembly overview: Drive axle with

II - Assembly overview: Drive axle

III - Assembly overview: Drive axle

IV - Assembly overview: Drive axle

7, Drive axle with Triple-roller joint

Difference of drive axles in installed condition

VL100 VL107 AAR2600i AAR3300i

Fastening drive axle bolt, loosening and tightening

Special tools, testers and auxiliary items required

 Angle wrench V.A.G 1756

The wheel bearings must not be loaded when drive axle

If bearings are loaded by vehicles own weight the wheel

 Procedure for loosening bolt.

Vehicles without drive axle must not be moved, otherwise

- Instead of drive axle, install an outer joint.

- Tighten outer joint to 120 Nm.

Loosen hex bolt.

- With vehicle sitting on its wheels, loosen bolt up to 90 ,

- Lift vehicle until wheels hang freely.

- Apply brake (second technician required).

- Remove bolt - arrow - .

Tighten hex bolt.

 To tighten the drive axle, the wheels must still not

- Apply brake (second technician required).

- Tighten bolt to 200 Nm.

- Lower vehicle onto its wheels.

- Turn bolt an additional 180 .

Drive axle, removing and installing

Special tools, testers and auxiliary items required

 Torque wrench V.A.G 1332

 Angle wrench V.A.G 1756

When disassembling and performing repairs on

Drive axle with constant velocity (CV) joint, removing

- Loosen drive axle hex bolt 40-7, Fastening drive axle

 The vehicle must not be sitting on its wheels,

- Remove lower sound insulation

Repair Manual, Body Exterior, Repair Group 50, Sound

- Disconnect axle shaft from transmission axle flange.

- Push outer joint out of wheel hub by hand.

- Remove nuts - arrows - .

- Pull drive axle out of wheel hub.

Drive axle with constant velocity (CV) joint, installing

Remove any paint residue and/or corrosion on

- Install drive axle.

- Insert outer joint as far as possible into spline in wheel

- Fasten ball joint to control arm - arrows - .

 Check boot for damage or twisting.

- Install inner joint of drive axle and initially tighten bolts

- Tighten multi-point socket head bolts diagonally to torque

- Install lower sound insulation

Repair Manual, Body Exterior, Repair Group 50, Sound

- Tighten drive axle hex bolt.

 The vehicle must not be sitting on its wheels,

- Install and fasten wheel 44-2, Torque specification for

Torque specifications 40-3, Front axle, torque

Drive axle with Triple-roller joint AAR2600i and AAR3300i

- Loosen drive axle hex bolt 40-7, Fastening drive axle

- Remove lower sound insulation

Repair Manual, Body Exterior, Repair Group 50, Sound

- Remove nuts - arrows - .

Angle wrench V.A.G 1756

Procedure for loosening bolt.

To tighten the drive axle, the wheels must still not

Torque wrench V.A.G 1332

Angle wrench V.A.G 1756

The vehicle must not be sitting on its wheels,

Check boot for damage or twisting.

The vehicle must not be sitting on its wheels,

Do not use a hammer or other impact tool under any

Check boot for damage or twisting.

The vehicle must not be sitting on its wheels,

Check boot for damage or twisting.

The vehicle must not be sitting on its wheels,

Outer constant velocity joint

Replace only as a unit

Removing 40-7, Pressing

Installing: Using a plastic

Checking 40-7, Outer

Hex head bolt

Replace each time it is

Right axle shaft

Replace each time it is

Tightening 40-7, Tighten

Check for tears and chafing

Replace each time it is

Installed location 40-7,

Installed location 40-7,

Replace each time it is

Insert in groove in shaft

Constant velocity joint boots

Check for tears and chafing

Drive off constant velocity

Before installing on constant

Replace each time it is

Tightening 40-7, Tighten

Left axle shaft

Multi-point socket head bolt

Torque specification Topic

After disassembly, always

Remove and install using

Inner constant velocity joint