Drive Axle, with 88 mm Outer CV Joint
Drive Axle, 88 mm Outer CV Joint
Assembly overview, refer to => [ Drive Axle Assembly Overview, 88 mm Outer CV Joint ] Drive Axle Assembly Overview, 88 mm Outer CV Joint.
Special tools, testers and auxiliary items required
• Thrust plate (VW 401)
• Thrust plate (VW 402)
• Punch (VW 409)
• Thrust Disc (VW 412)
• Sleeve press tool (VW 522)
• Press block (40-204A)
• Assembly tool (T10065) can also be used instead of (40-204A).
• Adapter plates (2036/1)
• Press support - R&I wheel bearings (3144)
• Hose clamp pliers (VAG 1275)
• Torque wrench (40-200 Nm) (VAG 1332)
• CV joint boot clamp tool (VAG 1682)
• Assembly tool (T10065)
• Sealant
• Circlip pliers (commercially available)
Inner CV Joint, Servicing
Inner CV Joint, Removing
- Secure the drive axle with protective covers in a vise.
- Pry off cap with a screwdriver.
- Remove the gasket - arrow -.
- Drive off the cap from the CV joint boot using a brass or copper drift.
• Clamp must not be loosened.
- Remove the circlip.
- Press the inner CV joint off of the axle shaft with the special tools shown in the illustration.
- Open the small clamp on the axle shaft and remove the CV joint boot from the axle shaft.
Inner CV Joint, Installing
- Apply sealant -hatched surface- to a clean surface on the inner side of the CV joint boot cover. Sealant bead: Uninterrupted 2 to 3 mm diameter in the area of the inner holes - arrow -.
- Use sealant.
- Slide the CV joint boot with the small clamp onto the axle shaft.
- Before installing the CV joint, coat the splines - A - lightly with the same grease used in the CV joint.
The CV joint boot and cap contact surfaces must be free of grease!
- Press on the CV joint until seated.
Chamfer on the inner diameter of ball hub (splines) must face the contact shoulder on the axle shaft.
Use the special tools shown in the illustration.
You can also use the (T10065) instead of the (40-204A).
(40-204A) or (T10065) and clamping surfaces on the axle shaft must be free of grease.
Circlip must be replaced.
- Install the circlip.
- Check the circlip for correct seating.
- Before installing the cover, apply 60 grams of drive axle grease in CV joint through the ball paths.
Make sure you do not damage the sealant bead.
- Align the cap using bolts - arrows - with the bolt holes.
It must be aligned exactly because it cannot be aligned after driving on.
- Drive cover on using a plastic hammer.
- Wipe away any sealant leaking out.
- Apply 60 grams of joint grease to the CV joint through the ball paths.
- Lubricate the contact surfaces for the gasket.
- Remove the adhesive foil from gasket and adhere to the CV joint.
- Align the new cover - A - to the bolt holes.
It must be aligned exactly because it cannot be aligned after pressing on.
- Press on the cap - A - using special tools shown in the illustration.
Flat steel in an appropriate size can be used instead of the (2036/1).
- Position the CV joint boot in the outer groove - arrow 2 -.
Inner groove - arrow 1 - must remain visible "identifying groove" (for correct installation of the CV joint boot).
Inner CV Joint Boot Clamp, Installing
- Use the (VAG 1682) as shown in the illustration. Be sure that edges of the (VAG 1682) are seated in the corners - arrows B - of the clamp.
- Tighten the clamp by turning the spindle using a torque wrench - C - (do not tilt the (VAG 1682)).
• A stainless steel clamp must be used due to the hardness of the CV joint boot material (compared to rubber). This clamp can only be tensioned using the (VAG 1682).
• Tightening specification: 20 Nm.
• Use a torque wrench with 5 to 50 Nm range (for example, (VAG 1331)).
• Make sure the spindle threads - A - on the (VAG 1682) move freely. Grease with MoS2 grease if necessary.
• If they do not move freely, due to dirt in the threads , the required clamp tension will not be achieved at the specified torque.
Inner CV Joint, Checking
In order to replace grease in case of strong contamination or if the journal surfaces and ball bearings must be checked for wear and damage the CV joint must be disassembled.
Disassembling
• Ball hub and joint are paired and should be identified before removal. Do not interchange cage allocation.
- Swing the ball hub and ball cage.
- Press out the ball joint housing in the - direction of the arrow -.
- Press the ball bearings out of the cage.
- Flip out the ball hub from the ball cage via the running path of ball bearing - arrows -.
- Check the joint piece, ball hub, ball cage and ball bearings for small broken off depressions (pitting buildup) and chafing.
• Excessive circumferential backlash in the joint makes itself noticed via tip-in shock. Joint must be replaced in such cases. Flattening and running marks of balls are no reason to replace joint.
Assembling
- Insert the ball hub into the ball cage via two chamfers. The installation position is at random. Press the ball bearings into the cage.
- Insert the hub with cage and ball bearings upright into the joint piece.
• When inserting, make sure that in each case the wide gap - a - at joint piece contacts narrow gap - b - at hub after swinging in.
• Chamfer on inner diameter of wheel hub (splines) must face toward drive axle.
- Swing in ball hub, to do so swing out hub far enough from cage - arrows - so that the balls have the distance of the running paths.
- Swing in hub with balls by pressing forcefully onto cage - arrow -.
CV Joint, Checking for Function
CV joint is properly assembled, if ball hub can be slid back and forth by hand over whole compensation length.
- Press grease into joint body.
Drive axle with 88 mm diameter outer CV joint, grease quantities and types. Refer to => [ Grease Quantity and Type ] Drive Axle Assembly Overview, 88 mm Outer CV Joint.
Outer CV Joint, Servicing
Outer CV Joint, Removing
- Secure the drive axle with protective covers in a vise.
- Open both clamps and remove the CV joint boot from the outer CV joint.
- Strike a copper or brass drift - A - on the CV joint inner race with a hammer.
- Remove the CV joint and boot.
Outer CV Joint, Installing
- Slide the CV joint boot onto the axle shaft.
The CV joint and boots must be free of grease.
1 Circlip (snap ring), must be replaced.
- Position the CV joint boot between the - arrows -.
- Apply 40 grams of joint grease to the inside of the CV joint.
- Screw old the drive axle bolt into the CV joint as shown in the illustration.
- Drive the CV joint onto the axle shaft with plastic hammer until the circlip engages.
- Insert 50 grams of drive axle grease into the CV joint on the boot side.
Outer CV Joint Clamp, Installing
- Install the clamp on the outer CV joint.
- Bleed the protective CV joint boot.
- Tension clamp using the (VAG 1275).
Outer CV Joint, Checking
In order to replace grease in case of strong contamination of if the journal surface of the ball bearings must be checked for wear and damage the CV joint must be disassembled
Disassembling
- Mark the position of the ball hub to the ball cage and to the housing before disassembling, using a scribe or grindstone.
- Swing the ball hub and ball cage.
- Remove the ball bearings in sequence.
- Turn the cage, until two rectangular windows - arrow - contact the joint body.
- Lift out the cage with hub.
- Swing the hub segment with smaller pins into the rectangular window on the cage.
- Fold the hub out from the cage.
CV Joint, Checking for Function
6 ball bearings for each joint belong to a tolerance group. Check the stub axle, hub, cage and balls for small depressions (pitting buildup) and chafing. Excessive circumferential backlash in joint makes itself noticed via tip-in shock, in such cases joint should be replaced. Flattening and running marks of balls are no reason to replace joint.
Assembling
- Insert the cage with hub into the joint body.
• Cage must be installed laterally correct.
- Press in the opposing ball bearings in sequence, during this, previous position of ball hub to ball cage and to joint body must be reestablished.
- Press the grease into the joint body.
Drive axle with 88 mm diameter outer CV joint, grease quantities and types. Refer to => [ Grease Quantity and Type ] Drive Axle Assembly Overview, 88 mm Outer CV Joint.