In time the rubber coupling cracks, splits and swells. A genuine VW replacement can be purchased for around £8-10.
Replacing is clearly documented in Haynes manual Chapter 9.12. Here's additional findings from an average DIY'er.
Some models have four bolts. Later versions have two bolts and two factory rivets. My camper had the latter, meaning removal of flexible coupling and relay unit clamp.
Disconnect battery.
Well soaked in Plusgas and splines marked with tippex
Loosen pinch bolt and two securing bolts and remove coupling with clamp. Put the connecting rod to one side. Once apart DO NOT turn steering wheel.
Running a cutting blade (on angle grinder) between clamp and rubber coupling will release the two factory rivets. Now knock each rivet out with a drift. Or press out in a vice using a small bolt and correct size socket.
Old coupling in very poor condition
Attach new coupling with appropriate length M8 bolts, washers either side and nylock nuts. Torque to spec.
Lining up tippex marks replace pinch clamp with new coupling on to relay unit and add bolt and nut. But do not fully tighten. Reconnect shaft with the two bolts and nuts with washers. Tighten to spec. Finally tighten pinch bolt to spec. Both 20 nm.
Direction of nuts and bolts are purely down to ease of access and spanners
Manual says always use new self- locking bolts.
Access is tight. I did it without raising vehicle though. Disconnecting horn bulb helps.
Hope it helps.
Regards
Stuart
