Boot, Replacing

Special tools and workshop equipment required 

• Flanging Tool: T40261 
  Fig 1: Identifying Flanging Tool T40261

  Courtesy of AUDI OF AMERICA, LLC
• Hose Clamp: 23 to 35 mm Diameter 

Procedure 

-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

-- Clamp the driveshaft with the Flanging Tool - Protective Jaws : T40261/1  into the vise, as shown.

-- Carefully loosen the metal sleeve flanging -1- from the driveshaft joint at one place with a screwdriver.

• The surface on the driveshaft joint must not be damaged.

-- Using a side cutter, open the remaining flange -arrow- of the metal sleeve.

-- Remove the old boot with the metal sleeve from the driveshaft joint.

-- Destroy the support ring with the water pump -arrows- and remove the boot with the metal sleeve.

• The inside of the joint and the balls remain in the driveshaft joint.

-- Remove the excess old grease.

-- Grease the driveshaft joint with grease from the installation kit.

• Fill with the same amount of grease, that has been cleaned off plus the amount that remains in the old boot.

-- Clean the sealing surface -arrow- on the driveshaft joint -2-.

-- If grooves are created when removing the old boot, flatten them.

-- Place the new O-ring -1- in the groove.

-- Push the support ring -2- in the opening of the boot -1-.

• Installation direction: the recess -arrow A- is pushed in the boot.
• The guides -arrow B- for the support ring must be visible on the edge of the opening of the boot.

-- Fold up the boot -2- inward in the metal sleeve -1-.

-- Slide the hose clamp -arrow- onto the open guides for the support ring -3- as shown.

• The end of the support ring must be free.

-- Remove the hose clamp -2- until the guides -1- of the support ring can be inserted in the groove -3- of the inner section of the joint.

-- Loosen the hose clamp -2- and remove.

• The guides for the support ring must engage in the groove of the inner section -arrow-.

-- Push the metal sleeve of the boot all the way on the joint.

-- Attach the Flanging Tool: T40261  to the metal sleeve so that the guide roller stops -arrow- are touching the edge of the metal sleeve.

-- Flange the metal sleeve by turning the Flanging Tool: T40261  back and forth.

• The twist angle must be minimum 90° while turning it back and forth.
• While turning it back and forth, turn the hand wheel for the Flanging Tool: T40261  .
• The flanging is finished when the hand wheel for the Flanging Tool: T40261  can only be turned if a lot of force is used.