Drive shaft left-hand side, replace

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Julian Ross
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$"VCC126387 EN 20090226" file://c:\info\vv132007\ie\en\30\vcc126387.$ Removing the wheel and splash guards the left front wheel the splash guards under the engine the splash guard in the wheel arch.

Removing the wheel and splash guards the left front wheel the splash guards under the engine the splash guard in the wheel arch.

1 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 1 of 13 Drive shaft lefthand side, replace Special tools: Removal Removing the drive shaft nut the hub cap the drive shaft nut and washer. Removing the wheel and splash guards the left front wheel the splash guards under the engine the splash guard in the wheel arch. Disconnecting the drive shaft from the gearbox Remove the drive shaft from gearbox enough to free the snap ring in the differential drive. Use jimmy tool Disconnecting the drive shaft from the hub Hint: If the drive shaft sticks in the hub, tap it with a copper or rubber mallet. If necessary, use a universal puller. The drive shaft can be pressed in approximately 15 mm.

$"VCC126387 EN 20090226" file://c:\info\vv132007\ie\en\30\vcc126387.$

2 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 2 of 13 Removing components the brake hose from the mounting in the spring strut the ABS cable from its mounting in the wheel arch and on the spring strut the ABS sensor the stub axle from the spring strut. Removing the drive shaft Turn the wheel (steering to the right). Angle the stub axle and remove the drive shaft from the hub and gearbox. Caution! Do not damage the seal in the hub. Temporarily secure the stub axle to the spring strut with one of the screws. Caution! Ensure that no dirt gets into the wheel hub bearing. Installation Installing the left drive shaft Ensure that the ABS sensor pulse wheel on the drive shaft is free of dirt. Press in the drive shaft firmly so that the snap ring engages in its groove in the differential gear. Carefully pull the drive shaft constant velocity joint to check that the drive shaft is secure. Note! Ensure that the seal ring in the gearbox and the boot on the drive shaft are not damaged.

$"VCC126387 EN 20090226" file://c:\info\vv132007\ie\en\30\vcc126387.htm Page 3 of 13 Installing the drive shaft, stub axle, brake hose and ABS sensor Align the drive shaft in the hub.$

3 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 3 of 13 Installing the drive shaft, stub axle, brake hose and ABS sensor Align the drive shaft in the hub. Install: the screws on the stub axle. Use new lock nuts Tighten to: 90 Nm the brake hose with the retaining clip on the spring strut the ABS sensor the ABS line on the spring strut and the wheel arch. Install a new washer and new lock nuton the drive shaft. Tighten the nut lightly. Installing splash guards and the wheel Install: the splash guard in the wheel arch the splash guards under the gearbox and engine the wheel, seeinstalling wheels. Tightening the drive shaft nut Lower the car Apply the handbrake Move the gear selector to P Tighten the drive shaft nut. See Centre nut,

4 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 4 of 13 Tighten the drive shaft nut. See Centre nut, drive shaft and tightening torque Install the wheel cover. Drive shaft righthand side, replacing Removal Removing the drive shaft nut (Lefthand side in the illustration) the wheel cover the drive shaft nut. Removing the wheel and splash guards (Lefthand side in the illustration). Raise the car. the right front wheel the splash guards under the engine the splash guard in the wheel arch. Removing components (Lefthand side in the illustration). the brake hose from the mounting in the spring strut the ABS cable from the mounting on the spring strut the ABS sensor the stub axle from the spring strut.

$"VCC126387 EN 20090226" file://c:\info\vv132007\ie\en\30\vcc126387.htm Page 5 of 13 Cars with pilot bearings Remove the bearing cap.$

5 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 5 of 13 Cars with pilot bearings Remove the bearing cap. Disconnecting the drive shaft from the hub Hint: If the drive shaft sticks in the hub, tap it with a copper or rubber mallet. If necessary, use a universal puller. The drive shaft can be pressed in approximately 15 mm. Removing the drive shaft from the hub (Lefthand side in the illustration). Turn the wheel (steering left). Angle out the stub axle. Detach the drive shaft from the hub. Warning! Do not damage the seal in the hub. Clean the spline joint. Caution! Pull at the constant velocity joint, not the shaft, when removing the shaft. This is to help prevent excessive load on the joint axial stop. Do not damage the drive shaft seal and boots. Removing the right drive shaft Remove the right bearing cap for the drive shaft support bearing. Pull the drive shaft out of the gearbox. Pull the inner section of the shaft. Install the seal plug.

6 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 6 of 13 Installation Installing the right drive shaft on the gearbox Remove the seal plug. Caution! Take care not to damage the sealing ring in the gearbox or the boot on the drive shaft. Install the bearing cap. Tighten to 25 Nm. Installing the drive shaft, stub axle, brake hose and ABS sensor (Lefthand side in the illustration.) Align the drive shaft in the hub. Install: The screws for the stub axle. Use new lock nuts Tighten to: 90 Nm Brake hose with retaining clip on the spring strut the ABS sensor the ABScable on the spring strut. Install a new lock nut on the drive shaft. Tighten the nut lightly. Installing splash guards and the wheel Install: The splash guard in the wheel arch The splash guards under gearbox / engine The wheel. See Installing wheels. Tightening the drive shaft nut Lower the car Apply the handbrake Move the gear selector to P Tighten the drive shaft nut. See Centre nut, drive shaft and tightening torque Install the wheel cover.

$"VCC126387 EN 20090226" file://c:\info\vv132007\ie\en\30\vcc126387.htm Page 7 of 13 Install the wheel cover.$ Removing the boot Secure the drive shaft in a vice with soft jaws. Remove the clamps from the boot. Cut the boot and remove it from the shaft. Note!

Removing the boot Secure the drive shaft in a vice with soft jaws. Remove the clamps from the boot. Cut the boot and remove it from the shaft. Note!

7 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 7 of 13 Install the wheel cover. Replacing the drive shaft boot on the wheel side Special tools: , Preparations Remove the drive shaft. See Drive shafts, replace. Removing the boot Secure the drive shaft in a vice with soft jaws. Remove the clamps from the boot. Cut the boot and remove it from the shaft. Note! If only the joint is to be replaced and not the boot, pull the boot back and do not cut it. Clean the constant velocity joint Wipe off the grease from the constant velocity joint. Note the position of the constant velocity joint on the shaft in order to install it in the correct position later. Measure for example the distance from the inner ring to the inner groove on the shaft. Constant velocity joint with visible snap ring If the constant velocity joint has a visible snap ring, the snap ring must be held open and the constant velocity joint released. See Releasing

$"VCC126387 EN 20090226" file://c:\info\vv132007\ie\en\30\vcc126387.htm Page 8 of 13 constant velocity joint with visible snap ring. The snap ring is visible in a cutout on the inner ring.$ Inner boot If replacing both drive shaft boots, replace the inner boot according to Releasing constant velocity joint with visible snap ring. Cleaning the constant velocity joint Note!

Inner boot If replacing both drive shaft boots, replace the inner boot according to Releasing constant velocity joint with visible snap ring. Cleaning the constant velocity joint Note!

8 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 8 of 13 constant velocity joint with visible snap ring. The snap ring is visible in a cutout on the inner ring. Drive shaft without visible snap ring. Tap off the constant velocity joint housing Use a brass drift. Note! Only tap the inner ring. Take care not to damage the ball holder or outer ring. Inner boot If replacing both drive shaft boots, replace the inner boot according to Releasing constant velocity joint with visible snap ring. Cleaning the constant velocity joint Note! The joint can be cleaned when assembled and blown clean before greasing. For disassembly and inspection, see Cleaning and checking the outer constant velocity joint. Lubricating the constant velocity joint Lubricate the constant velocity joint thoroughly. The outer constant velocity joint requires 80 g of grease. Also apply grease behind the joint via the shaft hole in the inner ring. Use half of the grease packet. The remainder will be used later in the boot.

$"VCC126387 EN 20090226" file://c:\info\vv132007\ie\en\30\vcc126387.$ Ensure that inner ring is straight in the constant velocity joint. Tap in the constant velocity joint so that the snap ring slots into its groove. Use tool 999 2842 and a rubber mallet.

Ensure that inner ring is straight in the constant velocity joint. Tap in the constant velocity joint so that the snap ring slots into its groove. Use tool 999 2842 and a rubber mallet.

Ensure that there is no grease on the mating surfaces between the boot and the constant velocity joint and the shaft. Remove excess grease. Use methylated spirit.

9 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 9 of 13 Installation Install: the clamp on the drive shaft the new boot on the drive shaft a new snap ring the constant velocity joint on the drive shaft. Ensure that inner ring is straight in the constant velocity joint. Tap in the constant velocity joint so that the snap ring slots into its groove. Use tool and a rubber mallet. Check that the constant velocity joint is correctly positioned by checking the measurement made earlier. Applying grease in the boot Apply the remaining grease inside the boot. Note! Ensure that there is no grease on the mating surfaces between the boot and the constant velocity joint and the shaft. Remove excess grease. Use methylated spirit. Ensure that the boot is in position on the constant velocity joint housing. Install a new clamp. Use pliers Venting the boot Venting is carried out to remove any over pressure in the boot. Use a rounded screwdriver. Carefully insert the screwdriver between the drive shaft and boot. Ensure that the boot is in position on the drive shaft. Ensure that the boot is aligned against the inner rib on the drive shaft. Install a new clamp. Use pliers Install the drive shaft according todrive shafts, replace. Cleaning and checking the outer constant velocity joint Mark the outer ring for the outer constant velocity joint, the ball holder and inner ring. Mark components in relation to each other. Use an electric scriber.

$"VCC126387 EN 20090226" file://c:\info\vv132007\ie\en\30\vcc126387.$ Remove the ball bearings clockwise one by one. Use the marking as the starting point for removal.

Remove the ball bearings clockwise one by one. Use the marking as the starting point for removal.

Removing the ball holder and inner ring from the shaft Turn the inner ring 90 degrees in relation to the ball holder.

10 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 10 of 13 Removing the ball bearings Remove the ball bearings. Turn the inner joint ring and ball holder. Remove the ball bearings clockwise one by one. Use the marking as the starting point for removal. Place the ball bearings in order so that they can be reinstalled in the same positions. Removing the ball holder and inner ring from the shaft Turn the inner ring 90 degrees in relation to the ball holder. Remove the inner ring. Cleaning constant velocity joint components Thoroughly wash the components in the constant velocity joint. Note! Replace the drive shaft assembly if any component has cracking or wear damage. Scratches and minor pitting of the ball tracks are permitted.

$"VCC126387 EN 20090226" file://c:\info\vv132007\ie\en\30\vcc126387.htm Page 11 of 13 Installing the inner ring in the ball holder Locate the markings to each other. Install a ball bearing. Note!$ Releasing constant velocity joint with visible snap ring To facilitate removing the constant velocity joint, grind a drift as illustrated.

Releasing constant velocity joint with visible snap ring To facilitate removing the constant velocity joint, grind a drift as illustrated.

11 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 11 of 13 Installing the inner ring in the ball holder Locate the markings to each other. Install a ball bearing. Note! The location of the ball bearings. Turn the inner ring and the ball bearing holder. Install the balls one by one in the same positions as before. Releasing constant velocity joint with visible snap ring To facilitate removing the constant velocity joint, grind a drift as illustrated. Rounding the underside of the edge will stop the drift catching in the snap ring groove on the drive shaft. The slightly sharper angle (approximately 60 degrees) means that the drift has a greater mating surface against the inner ring. Freeing the constant velocity joint Secure the drive shaft in a vice. The notch for the snap ring must be upward. Hold the snap ring open. Place the altered drift between the snap ring. Tap out the inner ring on the constant velocity joint slightly on the shaft so that the snap ring remains in the open position. Replacing the inner boot Measure and note the vibration damper location on the shaft. the clamps from the vibration damper the vibration damper.

$"VCC126387 EN 20090226" file://c:\info\vv132007\ie\en\30\vcc126387.htm Page 12 of 13 Removing the boot Remove the clamps from the inner boot. Cut the boot and remove it from the shaft.$ Lubricate the constant velocity joint thoroughly. The inner constant velocity joint requires 120 g of grease. Apply half the amount of the grease package. The remainder will be used later in the boot.

Lubricate the constant velocity joint thoroughly. The inner constant velocity joint requires 120 g of grease. Apply half the amount of the grease package. The remainder will be used later in the boot.

12 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 12 of 13 Removing the boot Remove the clamps from the inner boot. Cut the boot and remove it from the shaft. Cleaning and greasing Note! The inner constant velocity joint can be cleaned while assembled and blown clean. Note! If the joint needs to be disassembled and inspected, see Replacing the drive shaft boot on the gearbox side. Lubricate the constant velocity joint thoroughly. The inner constant velocity joint requires 120 g of grease. Apply half the amount of the grease package. The remainder will be used later in the boot. Installing the boot Thread the boot onto the shaft. Apply the remaining grease inside the boot. Note! Ensure that there is no grease on the mating surfaces between the boot and the constant velocity joint and the shaft. Remove excess grease. Use methylated spirit. Ensure that the boot is in position on the constant velocity joint housing. Install a new clamp. Use pliers

13 "VCC EN " file://c:\info\vv132007\ie\en\30\vcc htm Page 13 of 13 Venting the boot Venting is carried out to remove any over pressure in the boot. Use a rounded screwdriver. Carefully insert the screwdriver between the drive shaft and boot. Ensure that the boot is in position on the drive shaft. Ensure that the boot is aligned against the inner rib on the drive shaft. Install a new clamp. Use pliers The drive shaft and vibration damper Clean off any grease and dirt from the drive shaft. Install the vibration damper following the measurement made earlier. Hint: To enable the vibration damper to slide more easily, apply a soap solution to the shaft and hole in the vibration damper. Install new clamps.

Constant velocity joints, inner

"VCC001037 EN 20120826" 1(2) Constant velocity joints, inner Special tools: 951 2619 Note! For removing drive shafts Removing drive shafts. The method is the same for the left and right drive shaft. Expose