Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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If your CV is leaking grease (see 1.1) or has oil dripping from it you will need to replace the axle oil seal. To do this you will need to remove the CV joint. It is best to buy a kit that contains new seals and king pin bearings. You may as well replace them all while you have the CV out. 1.1 Leaking CV Removal 1. Loosen the wheel nuts then jack up the vehicle and put axle stands under the axle housing on each side. Remove the road wheels then, remove the disc break calliper buy undoing the two bolts at the back of the calliper. Tie the calliper to the top of the shock. 2. Remove the free wheeling hub outer cover. Undo the outer bolts first and remove the front of the hub. You will then need to remove the C clip (1.3) so you can take of the rest of the hub. 1.2 Remove free wheeling hub 1.3 Remove the C clip and take of the rest of the hub 3. Bend the wheel bearing locking tab and undo the wheel bearing locknuts. 1.4 Remove the wheel bearing lock nuts 4. Undo the four bolts holding the back plate and spindle and take off the back plate. 5. Mark the spincle so you can replace it in the same position. Also mark the king pins so they can also be reinstalled in the same position. Use something that won’t come off when you are cleaning the parts. 1.6 mark spindle and king pins before removal 6. Remove the diff oil but undoing the bottom plug in the diff housing. 7. Take out the split pin in the tie-rod nut remove the nut and separate the tie-rod from the steering knuckle with a wheel puller. 1.8 Separate the tie-rod from the steering knuckle 8. Remove the king pins and make sure you know which one is the top and which one is the bottom. 9. You can know take off the steering knuckle. If you are not replacing the king pin bearings be careful as the bottom bearing will fall out when you take of the steering knuckle. 10. Withdraw the CV and axle out and clean all the old grease off the CV and housing.

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Boot, half shaft, replacing Special tools: 951 2619, 999 2412 Disassembly Note: Preparatory work, see Axle Shaft Assembly; Service and Repair. Remove the boot Secure the drive shaft in a vise with soft jaws. Remove the clamps from the boots. Cut the boot and remove it from the shaft. Check the measurement Wipe off the grease from the constant velocity joint housing. Measure the distance from the inner ring to the inner groove on the shaft. Note the measurement. 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. For cleaning/assembly and greasing the outer joint, see below

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Removal CAUTION: Do not begin this procedure unless the following parts are available: a new front axle wheel hub retainer
a new front suspension lower arm-to-ball joint nut a new circlip Do not reuse these parts during assembly. Their torque retention
capability diminishes during removal. NOTE: This procedure applies to both the LH and RH halfshaft assemblies. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. Failure to turn off the air suspension switch can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. With the transmission in neutral, raise and support the vehicle. 2. Remove the front wheel and tire assembly.

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AXLE SHAFTS – FRONT 1991-92 DRIVE AXLES FWD Axle Shafts Axle shafts transfer power from transaxle to drive wheels. Axle shafts consist of a shaft and flexible Constant Velocity (CV) joint at each end. See Fig. 1 . Inner CV joint is splined to transaxle. Outer CV joint is splined to hub assembly and secured by wheel bearing lock nut. Inner CV joint is a plunging tripod joint. The plunging action allows for axle shaft length change as suspension Inner and outer CV joints are enclosed by a CV joint boot. The boot maintains lubrication in the joint and prevents contamination of CV lubricant. Boots must be replaced when leakage or cracks are present. The inner CV joint can be repaired without replacing assembly. The outer CV joint must be replaced as an assembly.

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Special tools, testers and auxiliary items required Thrust Plate VW 401 Thrust Plate VW 402 Assembly Tool T10065 Tube 37mm dia. VW 416 B Punch VW 411 Thrust Pad VW 447 H Special tools, testers and auxiliary items required Assembly/removal tool T40018 Disassembling Clamp drive shaft horizontally into vise. Note: Use protective jaws. Make sure the drive axle is not damaged. Mark position of joint piece to drive axle. If installation positions are not marked and components are not reinstalled in previous positions, noises may occur later during driving operation. A water-proof felt pen is well-suited for marking. Remove clamps – arrows – . Slide back CV boot. Guide Assembly/Removal tool T40018 in behind joint piece. Guide pin – 1 – must make contact with exterior of joint piece. Bring Assembly/Removal tool T40018 into contact at joint piece by turning knurled bolt – 2 – . Note: Joint piece must be secured in Assembly/Removal tool T40018 without play. Only hand tighten bolts – 2 – . Screw Slide Hammer-complete Set VW 771 into Assembly/Removal tool T40018 . Pull off joint piece horizontally using Slide Hammer-complete Set VW 771 . Keep joint piece in Assembly/Removal tool T40018 . Mark installation position of parts – 1 – and – 2 – with lines. If the parts are not marked and the parts are not reinstalled in their previously installed positions, noises may occur later during driving operation. A water-proof felt pen is well-suited for marking. 1 – Drive shaft 2 – Triple roller star Remove grease with a lint free rag.