VW Passat B5

since 1996 release

Repair and operation of the car



Foltsvagen Passat B5
+ Maintenance instruction
+ 1. Maintenance
+ 2. Engines
+ 3. Cooling system
+ 4. Fuel system
+ 5. Engine management
+ 6. Exhaust system
+ 7. Transmission
- 8. Running gear
   - 8.1.2. Depreciation rack
      8.1.2.1. Repair of a depreciation rack
      8.1.3. Removal and installation of a power shaft
      8.1.4. Amount of G 000 603 lubricant for external hinges of power shafts
      8.1.5. Lubricant of the internal three-humeral hinge
      8.1.6. Filling of the CV JOINT with G6 lubricant
      8.1.7. Replacement of the internal hinge of equal angular speeds
      8.1.8. Replacement of the external hinge of equal angular speeds
      8.1.9. Dismantling of the external hinge of equal angular speeds
      8.1.10. Malfunctions of power shafts
   + 8.2. Back suspension bracket
   + 8.3. Wheels and tires
+ 9. Steering
+ 10. Brake system
+ 11. Body
+ 12. Heating, ventilation
+ 13. Electric equipment






8.1.7. Replacement of the internal hinge of equal angular speeds

GENERAL INFORMATION

Power shaft with the ball hinge

1 – lock ring,
2 – laying,
3 – internal CV JOINT,
4 – power shaft,
5 – collar,
6 – protective cover,
7 – collar,
8 – washer,
9 – persistent ring,
10 – lock ring,
11 – external CV JOINT,
12 – bolt,
13 – bolt,
14 – plate,
15 – a protective cover of the hinge with a flange

Prevention

Removal of a lock ring 1 is made with use of kruglogubets.

At installation of new laying 2 it is necessary to use new laying. Remove a protective film from laying and paste laying to the hinge.

Depending on the power unit the internal CV JOINT 3 with a diameter of 100 or 108 mm is used.

At installation of collars 5, 7 it is necessary to use new collars.

In the presence of attritions or cracks it is necessary to use a new protective cover 6. Before installation of a smaller collar of fastening of a protective cover let out the air from under a protective cover.

At installation of a washer 8, the concave party of a washer has to adjoin to a persistent ring.

At installation of a lock ring 10 it is necessary to use a new lock ring. Before installation of the hinge it is necessary to establish a lock ring in a flute of a power shaft.

Depending on the power unit the external CV JOINT 11 with a diameter of 88 or 98 mm is used. Replacement of the CV JOINT is made assembled. At installation press the CV JOINT the plastic hammer on a power shaft before fixing by its lock ring.

At installation it is desirable to use a new bolt 12. When tightening a bolt the 12th car has to stand on wheels.

Moments of tightening of a bolt 12:
  – + to tighten a bolt of M14 115 Nanometers on a corner 180 °,
  – + to tighten a bolt of M16 190 Nanometers on a corner 180 °.

Moments of tightening of a bolt 13:
  – bolt of M8 40 Nanometers,
  – bolt of M10 80 Nanometers.

 In a protective cover of the hinge with a flange 15 there is an opening for production of air. In the presence of attritions or cracks it is necessary to use a new protective cover. Before assembly of the CV JOINT apply a thin film of D3 sealant on a flange.


The internal hinge of equal angular speeds is not under repair, and in case of its exit out of operation, it is subject to replacement completely.

PERFORMANCE ORDER
1. Fix a power shaft in a vice with soft sponges.
2. Using special nippers for removal of spring lock rings, remove a lock ring from the end of the internal hinge of equal angular speeds.
3. Using a mandrel, bring down a protective cap from the hinge. The mandrel needs to be established in turn in various points on cap perimeter, for its uniform removal. Move a protective cover on the middle of a power shaft.
4. Fix the internal hinge in a vice, then take from it a power shaft. If the power shaft does not give in to extraction from the hinge, install the hinge under a press and, using VW 402 and VW 408a devices, squeeze out from it a power shaft.
5. Remove a dish-shaped spring washer from a power shaft, previously having noted its situation. The washer has vents, and the convex party of a washer is from the hinge.
6. Before installation of the new hinge carefully clear a power shaft.
7. Establish a spring dish-shaped washer on a shaft so that the convex party of a washer was from the hinge, and internal vents of a washer were combined with shaft vents.
8. Fix the internal hinge of equal angular speeds in a vice with soft sponges and insert into it a power shaft. In case the shaft does not enter the hinge, press the hinge on a shaft on the press, at the same time the shaft from below has to lean on a support.
9. Establish a new spring lock ring in a flute of a power shaft.
10. Fill the internal hinge with 120 grams of lubricant, and put one half of lubricant in the hinge on the one hand, and the second half – on the other hand.
11. Establish into place a protective cover. Before fastening of a protective cover collars, the screw-driver raise an inner edge of a cover, for alignment of pressure of air under a cover.
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