Disassemble the outer joint of the driveshaft

Hello diesel mechanics,

After 220,000 kilometers, it was time to replace the ball joints of the outer drive shafts.
One is cunning, the other is on the verge.

Disassemble the wave components completely and then use the large [tool/mechanism] to remove the joint.
Looking down into the vise, it usually works fine, but it makes a short cracking sound and then it breaks.

Today, during the second attempt, I had a real problem; there was no cracking sound. However, it required enormous force to loosen the joint using a screwdriver.
It was very stiff and required a long thread engagement.
After the joint finally came off, I could see the reason why:
The retaining ring had sheared off between the shaft stub and the joint.
It's located on the part between the groove where the retaining ring is.
Three teeth were torn off, extending to the end of the wave (approximately 5mm).
Hopefully, I found all the pieces, and after some dental care, I let it go in the wave.
the joint can easily slip out of place again.

Have you ever experienced something like this before?
Is there a way to prevent this?


Good evening.

Faxes.

Yes, there is. You always have to open the retaining ring first by slightly pre-tensioning it and pushing it outwards!
Normally, your method won't detach the joint from the shaft.

Best regards, Bastianna.

Quote:

After the joint finally came off, I could see the reason: The retaining ring had sheared off between the shaft stub and the joint. It's located on the part between the groove where the retaining ring is. Three teeth were torn off, extending to the end of the wave (approximately 5mm).

This happens because the retaining ring is being squeezed before it can properly compress. Even a slight burr somewhere can cause the ring to get stuck and prevent it from moving. This has happened to me exactly once.
Since then, I've been using the formula "Force = Mass x Acceleration" again.

When done correctly, the joint can be loosened by striking the inner ring with a soft punch and a hammer that is slightly heavier than the joint itself, provided you know what you're doing. With this method, the retaining ring doesn't have time to get stuck or anything else, and I haven't damaged any of these shafts yet. However, it is not necessarily recommended for amateurs to try and replicate it.

Quote:

Yes, there is. You must always first open the retaining ring by applying slight tension and pushing it outwards! Normally, you won't detach the joint from the shaft using your method!

This does not apply to the outer joint of this driveshaft, as the retaining ring is not accessible from the outside.

Hi,
@ Bastianna - it may be that you are referring to a very specific model, but in all the Wellen products I have handled so far, the retaining ring under the outer joint disappears. You can only access that part if the joint is removed.
Typically, the joint is driven or expanded onto the shaft using a plastic hammer. That's how I always do it. Faxe's method probably works too.
@Faxe - You need to be careful not to overstretch the retaining ring (new one) when installing it. That might have been the issue here. Apply plenty of grease and press it into the groove until it snaps over the shaft. You might encounter the same problem during the next upgrade if the ring no longer sits securely in the damaged groove.
Okay, I understand. Please provide the German text you would like me to translate into English. I will only provide the translation.
Herbert.

Hello,

I'm adding my comment here because it's somewhat relevant to the topic.

I recently replaced the outer CV joint boot on my Audi A2. Compared to the Passat, the joint came off quite easily. Even hammering it in was easy and straightforward.

Despite using a new retaining ring, the driveshaft slipped out of the wheel bearing after about 150 km while I was turning. The cause was that the new retaining ring was broken approximately in the middle. There was nothing obviously wrong with the material (no cracks or similar). Now I'm wondering what went wrong, or if it was just bad luck. Are there any experiences with that?

Bye.
peace

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There was nothing unusual to see in the material (no lumps or anything like that). Now I'm wondering what went wrong, or if it was just bad luck. Are there any experiences with that?

...never had it before. I think it was just bad luck, or maybe you stretched the material too much during installation .