Drive shaft production

    Disassembly and maintenance of the drive shaft

    1. Remove the drive shaft from the bottom of the car as described in the previous section.

    2. Remove the inner constant velocity universal joint: Remove the two clamps on the rubber guard, and pull the guard onto the shaft to leave the universal joint.

    3. Use a suitable punch to remove the protective cover from the constant velocity universal joint.

    4. Remove the circlip at the end of the drive shaft.

    5. Hold the bottom of the ball cage and push out the drive shaft.

    6. Remove the rubber shield and protective cover from the drive shaft, and if there are elastic washers, remove them at the same time.

    7. Remove the outer constant velocity universal joint: Remove the two clamps on the rubber shield, and pull the shield onto the shaft to leave the universal joint.

    8. Remove the circlip and gently tap the inner edge of the inner hub with a soft metal punch to remove it from the shaft.

    9. Remove the rubber guard from the drive shaft.

    10. Before starting to disassemble the outer universal joint, mark the position of the inner hub relative to the cage and the outer shell. Because these parts are all quenched, they should be marked with oilstone or paint.

    11. Rotate the inner hub and the ball cage, and take out the steel balls one by one.

    12. Rotate the ball cage to two rectangular openings facing the outer shell, and then take out the ball cage and the inner hub.

    13. Rotate the inner hub and turn to an edge to push it into a rectangular opening on the ball cage, and then turn the inner hub out of the ball cage. The parts of the universal joint are matched, and individual parts cannot be replaced.

    When an excessive gap is found in the universal joint during the acceleration of the car and the acceleration of the car, a new universal joint should be installed, but not because of the parts The traces of being polished and the steel ball are clearly visible, so replace the universal joint.

    14. When assembling the universal joint, all the original grease should be wiped off, and the elastic retaining ring, rubber guard and clamp should be new. Only use special grease recommended by Audi to fill the universal joint.

    15. Squeeze half a bag of grease (45 grams) into the universal joint, and then install the ball cage and inner hub into the outer shell. When the steel ball is finished, the matching marks on the inner hub, the ball cage and the outer shell can be checked.

    16. Put the steel balls into the inner hub, and then install one side on the other side. After the six steel balls are installed, check the inner hub, the ball cage and the outer shell. The matching marks are not aligned.

    17. Install a new circlip in the groove of the inner hub, and squeeze the remaining grease into the universal joint, so that the total amount of grease Is 90 grams.

    18. The decomposition of the inner universal joint is similar to this. Rotate the inner hub and the ball cage and push them out of the outer shell.

    19. Push the steel ball out of the cage, then align the two grooves, and remove the inner hub from the cage.

    20. When assembling the universal joint, squeeze half of the grease into each side of the universal joint. Note that on four-cylinder engine models, the total amount of grease used for each inner universal joint is 90 grams, while on five-cylinder engine models it is 120 grams. Make sure that the chamfered side of the inner hub of the spline faces the larger diameter side of the housing. In order to align the ball with the groove during assembly, it is necessary to turn the inner hub of the universal joint.

    21. It is recommended to install a new rubber guard on the shaft. Causes abrasion in the joint. Install the guard on the shaft and put the remaining grease inside the guard.

    22. If there is a dish washer, install it on the inner end of the drive shaft and place the protective cover on the shield. Note that the concave surface of the dish washer must face the universal joint (see Figure 10-10).

    23. Press the inner universal joint onto the shaft and clamp it with a new circlip.

    24. Knock the protective cover onto the housing.

    25. Place the outer universal joint directly on the end of the drive shaft and use a mallet to beat the shaft into the universal joint until the elastic retaining ring enters the groove.

    26. Install new clamps on both ends of the rubber shield, cover the universal joint with the shield, and tighten the clamp. If the rubber guard fitted to the inner universal joint has a vent hole, the inner (small) clamp should not be installed.

    27. If available, install a new gasket on the mating surface of the inner universal joint, peel off the protective film, and glue the gasket to the mating Surface.