Volkswagen Golf / Golf Plus. Manual - part 27

 

  Index      Volkswagen     Volkswagen Golf (2004) / Golf Plus (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  25  26  27  28   ..

 

 

Volkswagen Golf / Golf Plus. Manual - part 27

 

 

Excessive circumferential backlash in the joint is noticeable dur‐

ing load change jolts. In this case the joint must be replaced.

Smoothing and traces of wear of the balls are no reason to renew

the joint.
Installing

– Insert hub into cage via the two chamfers. The hub can be

installed in any position. Press balls into cage.

The ball hub has two different distances between the ball tracks:

a smaller one and a larger one.

– Insert hub complete with cage and balls into joint body, making

sure that a smaller gap -b- faces open side of joint body.

– Also make sure that chamfer on inner circumference of ball

hub is visible after swinging it into place.

– Swing ball hub into place by swinging hub out of cage as

shown in figure -arrows-.

8. Assembly overview - drive shaft with VL90 or VL100 constant velocity joint    

105

 

Checking function of constant velocity joint
The constant velocity joint is correctly assembled if the ball hub

can be moved by hand backwards and forwards over its entire

range of axial movement.

106

     Rep. Gr.40 - Front suspension

 

(bolt-on)

1 - Outer constant velocity joint

❑ Renew only as com‐

plete unit

❑ Removing 

⇒ page 110

 .

❑ Installing: drive onto

shaft to stop using a

plastic mallet

❑ Checking 

⇒ page 103

2 - Bolt

❑ M16 x 1.5 x 80
❑ Hexagon bolt, 200 Nm

and turn +180° further

❑ 12-point bolt, 70 Nm +

90° further

❑ Always renew after re‐

moving

When bolt is loosened or tight‐

ened, vehicle must not be

standing on its wheels

3 - Hose clip

❑ Always renew after re‐

moving

❑ Tightening 

⇒ page 113

4 - Boot

❑ Check for splits and

chafing

❑ Material: Hytrel (poly‐

ester elastomer)

5 - Hose clip

❑ Always renew after re‐

moving

❑ Tightening 

⇒ page 113

6 - Dished spring

❑ Installation position 

⇒ page 111

7 - Thrust washer

❑ Installation position 

⇒ page 111

8 - Retaining ring

❑ Always renew after removing
❑ Insert in groove in shaft

9 - Boot for constant velocity joint

❑ Material: Hytrel (polyester elastomer)
❑ Without breather hole
❑ Check for splits and chafing
❑ Drive off constant velocity joint with a drift
❑ Coat sealing surface with D 454 300 A2 before installing constant velocity joint

10 - Dished spring

❑ Installation position 

⇒ page 111

9. Assembly overview - drive shaft with VL107 constant velocity joint (bolt-on)    

107

 

⇒ page 113

12 - Drive shaft
13 - Intermediate shaft

❑ For Golf only
❑ Right side of vehicle:
❑ Removing and installing 

⇒ page 92

❑ Repairing 

⇒ page 114

14 - Cover

❑ Always renew after removing
❑ Always renew
❑ Pressing off 

⇒ page 111

15 - Retaining ring

❑ Remove and install with circlip pliers -VW 161 A-

16 - Seal

❑ Adhesive surface on constant velocity joint must be free of oil and grease!

17 - Inner constant velocity joint

❑ Renew only as complete unit
❑ Pressing off 

⇒ page 111

❑ Pressing on 

⇒ page 112

❑ Checking 

⇒ page 104

18 - Cap

❑ Drive off carefully with drift
❑ Coat sealing surface with D 454 300 A2 before installing constant velocity joint
❑ Adhesive surface must be free of oil and grease!

19 - Locking plate

❑ Renew each time after removing

20 - Multi-point socket head bolt

❑ Initially tighten diagonally to 10 Nm and then tighten diagonally to specified torque.

M8 bolt: 40 Nm

M10 bolt: 70 Nm

❑ Always renew bolts after removing

21 - Hose clip

❑ Always renew after removing
❑ Tightening 

⇒ page 113

22 - Bolt

❑ 20 Nm
❑ For Golf only

23 - Countersunk head bolt

❑ Initially tighten to 5 Nm and then to 35 Nm
❑ For Golf only
❑ Qty. 3

24 - Bearing bracket

❑ For Golf only

108

     Rep. Gr.40 - Front suspension

 

 

 

 

 

 

 

 

Content   ..  25  26  27  28   ..