Overhaul

Driveshaft with Inner CV Joint, 100 mm Diameter





Special tools, testers and auxiliary items required

• Thrust plate (VW 401)

• Thrust plate (VW 402)

• Punch (VW 412)

• Clamp (40-204 A)

• Support sleeve (VW 522)

• Punch (VW 411)

• Hose clamp pliers (V.A.G 1275)





Grease quantity and type

CV joints are packed with grease G 000 603:





Regrease joint when replacing CV boot.

Pressing off outer CV joint





- Secure driveshaft with protective covers in vise clamp.

- Loosen clamp and turn back protective boot.

- Drive CV joint from drive axle using a drift - A -.

Drift must be placed precisely on star of CV joint.

Driving joint on

- Before installing joint piece, splines - A - must be lightly coated with grease used in joint.





- Insert sealing ring in groove on shaft.

- Slide on CV joint up to sealing ring.





- Align sealing ring at center with opening upward - see arrows -.

- Drive onto shaft with plastic hammer until securing ring engages.

Tighten clamp





Drive off cover for inner joint





Pressing off inner constant velocity joint





- Rebound circlip

- Drive off protective boot with drift.

• Support ball hub with thrust plate (VW 402).

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.





Use support sleeve (VW 522)

- Install lock ring.

• Position ball hub with chamfer on inner diameter (splines) on driveshaft.

Coat cover or cap sealing surface with D 454 300 A2





- Apply sealant -hatched surface- to clean cover or cap surface. Sealant bead: unbroken, dia. 2 to 3 mm, skirt area around inner holes - arrow -.

- Align cover and cap to screw holes and drive or press onto joint.

- Clear away leaking sealing immediately.