Volkswagen Type II Transporter 1200 Series Shop Manual page 120

39-Transmission and Rear Axle
!l. DRIVE SHAFTS
TO REMOVE CONSTANT VELOCITY JOINTS
(1) Undo the Allen head bolts from the flanges of the
drive shaft. Tilt the shafts downward and remove them
complete.
(2) Slacken the hose clips from both ends of the rubber
seals and slide the seals back along the shaft.
(3) From the front end of the ball hub, remove the cap
and circlip.
(4) Using a punch, knock the protective cap back off
the outer ring of the joint.
NOTE: With the protective cap removed, avoid swinging
the ball hub more than 20° in the outer ring of the joint as
the balls can fall out.
(5) Push the outer ring of the joint complete with balls
on to the ball hub.
(6) Press the drive shaft from the ball hub and remove
the dished washer.
TO INSTAL CONSTANT VELOCITY JOINTS
(1) Carefully check the condition of the drive shafts,
seals, constant velocity joints, protective caps and dished
washers for wear or damage and renew parts if necessary.
(2) Discard old hose clips and position new clips on the
shafts.
(3) Protect the seal from damage from the splines by
sliding a sleeve on the splines and instal the seal.
(4) Using a rubber head hammer, drive the protective
cap on to the shaft.
NOTE: The joint, when being positioned, should have the
face with the milled recess, towards the seal.
(5) After positioning the dished washer, the constant
velocity joint should be pressed on to the shaft.
(6) Position a new circlip and press it down until it
snugly seats in the groove.
(7) Using adjustable pliers, squeeze the circlip until it is
firmly seated in the groove.
(8) Pack the joint with special lithium grease. The joint
capacity is 120 grams.
~-BOLTS
AND LOCK PLATES
JOINT ASSY
CIRCLIP
d
NOTE: Eighty grams of grease is packed between the joint,
protective cap and seal and forty grams is pressed into the
open joint from the front end.
(9) Fit the hose clips in position and tighten them
ensuring that grease is not present on the sealing surfaces.
(10) Using the hand, lightly squeeze the seal for grease
to enter the joint from the rear.
(11) Press in the dust cap and fit the plastic cap on the
joint. .
(12) Instal both drive shafts and secure the Allen head
screws.
TO DISMANTLE CONSTANT VELOCITY JOINTS
(1) As previously described press the constant velocity
joint off the drive shaft.
(2) From one side of the outer ring of the joirit, press
out the ball hub and cage.
(3) With the ball hub and cage removed, remove the
balls from the cage.
NOTE: The ball hub and outer ring are not interchangeahle
as they are matched together. Five tolerance grades are
marked by 1-5 spots on the reverse of the outer ring and.
also on the side of the hub. There are six balls in each joint
which also belong to one tolerance group. and, therefore,
should only be renewed in sets.
( 4) Align two ball grooves in the ball hub with the ball
cage face and remove the hub from the cage.
TO ASSEMBLE CONSTANT VELOCITY JOINTS
(1) Carefully check the joint outer ring, ball hub, cage
and six balls for wear and renew parts if necessary.
NOTE: There must be no radial play, over the full range of
the sliding movement, between the ball hub and outer ring,
after installation of the balls and the cage.
(2) Insert the ball htib into the cage routing it through
two ball grooves in the hub. Positioning is not so important.
(3) Using balls of a matched set, press them into the
cage.
DRIVE SHAFT AND JOINT
/I
/
THRUST WASHER SMALL CLIP
FLANGE
Drive Shaft with one Constant Velocity Joint Removed.
120