Drive Axle Assembly Overview, With 108 mm Inner CV Joint
Drive Axle Assembly Overview, with 108 mm Inner CV Joint
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 409)
• Punch (VW 412)
• Support Sleeve (VW 522)
• Clamp (40-204 A)
• Assembly Tool (T10065/4)
Grease quantity and type
CV joints are packed with grease G 000 603:
Regrease joint when replacing CV boot.
1 - Cover
• Carefully drive off using a drift => [ Drive off cover for inner joint ] Overhaul
• Always replace
• Coat sealing surface with D 454 300 A2 before installing on CV joint => Overhaul
• Align cover to bolt holes
2 - Securing ring
• Remove and install with commercially-available circlip pliers
• Always replace
3 - Inner CV joint with protective boot cap
• Exterior diameter: 108 mm
• Replace only as complete unit
• Pressing off => [ Pressing off inner constant velocity joint ]
• Pressing on
• Greasing
• Adhesive surface must be free of oil and grease
• When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
4 - Backing plate
5 - Socket head bolt
• Tightening specifications:
M8 bolt: 40 Nm
M10 bolt: 65 Nm
6 - Clamp
• Always replace
• Tensioning => [ Tighten clamp ] Overhaul
7 - Protective boot for inner constant velocity joint
• With ventilation bore
• Check for tears and chafing; replace if necessary
• In case of damage, check inner CV joint, refer to => [ Inner CV Joint, Checking ] Inner CV Joint, Checking
• Protective boot/drive axle/cap sealing surfaces must be free of grease at installation
8 - Axle shaft
9 - CV boot for outer constant velocity (CV) joint
• Exterior diameter: 88 mm
• Without ventilation bore
• Check for tears and chafing; replace if necessary
• In case of damage, check outer CV joint => [ Outer CV Joint, Checking ] Outer CV Joint, Checking
• Protective boot/drive axle/joint sealing surfaces must be free of grease at installation
10 - Clamp
• Always replace
• Tensioning => [ Tighten clamp ] Overhaul
11 - Securing ring
• Always replace
• Insert in shaft groove
12 - Outer constant velocity joint
• Replace only as complete unit
• Driving off => Overhaul
• Installing: Drive onto shaft using plastic hammer until compressed circlip seats.
• Circlip must lie in joint chamfer when guiding in, guide with pliers if necessary.
• Greasing
• When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
13 - Collar bolt
• Always replace
Pressing off inner constant velocity joint
- Rebound circlip
- Drive off protective boot with drift.
• Cap - A - must not be supported on Thrust Plate (VW 401). Use segments (T10065/4 ) as spacers.
Pressing on inner CV joint
- Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
- Press on joint until stop.
- Install lock ring.
• Position ball hub with chamfer on inner diameter (splines) on drive axle.