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Drive Axle With 100 mm Inner CV Joint






Drive Axle with 100 mm Inner CV Joint

Special tools, testers and auxiliary items required

Thrust Plate (VW 401)

Thrust Plate (VW 402)

Punch (VW 408 A)

Punch (VW 411)

Tube 37 mm Diameter (VW 416 B)

Thrust Pad (VW 447 H)

Circlip Pliers (VW 161 A)

Torque Wrench 5-50 Nm (V.A.G 1331)

Torque Wrench 40-200 Nm (V.A.G 1332)

CV Joint Boot Clamp Tool (V.A.G 1682)

Assembly Tool (T10065)

Filling the Joints with Grease






Grease joint again when replacing protective joint boot.






1 - Outer CV Joint

Replace only as complete unit.

Checking, refer to => [ Outer CV Joint, Checking ] Outer CV Joint, Checking

Removing, refer to => [ Disassembling Outer CV Joint ]

Grease => table

Installing

When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.

2 - Bolt

Hex bolt = 200 Nm + 180° additional turn => [ Hex Bolt between Drive Axle and Wheel Hub, Loosening and Tightening ] Hex Bolt Between Drive Axle and Wheel Hub, Loosening and Tightening.

Twelve-point bolt with ribs = 70 Nm + 90° additional turn, refer to => [ Twelve-Point Bolt with Ribs, Loosening and Tightening, Drive Axle to Wheel Hub ] Twelve-Point Bolt With Ribs, Loosening and Tightening, Drive Axle to Wheel Hub.

Twelve-point bolt without ribs = 200 Nm +180° additional turn, loosening and tightening refer to => [ Twelve-Point Bolt without Ribs, Loosening and Tightening, Drive Axle to Wheel Hub ] Twelve-Point Bolt Without Ribs, Loosening and Tightening, Drive Axle to Wheel Hub

Different versions, allocation, refer to the Parts Catalog

Always replace if removed.

Before installing, clean the threads in the CV joint with a tap.

3 - Profile Shaft

4 - Clamp

Replace

Tensioning, refer to => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ] or => [ Clamps for Rubber Protective Joint Boots, Tensioning ]

5 - CV Boot for Outer CV Joint

Without vent hole

Check for tears and scuffing

6 - Clamp

Replace

Tensioning, refer to => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ] or => [ Clamps for Rubber Protective Joint Boots, Tensioning ]

7 - Plate Spring

Installed position, refer to => [ Installed location of spring washer and thrust washer on outer joint. ]

8 - Spacer Ring (plastic)

Installed position, refer to => [ Installed location of spring washer and thrust washer on outer joint. ]

9 - Locking Ring

Replace

Insert in shaft groove

10 - Protective Boot for Inner CV Joint

Without vent hole

Check for tears and scuffing

Drive off CV joint using drift

Coat the sealing surface of the CV joint with sealant before installing. Refer to the Parts Catalog.

11 - Clamp

Replace

Tensioning, refer to => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ] or => [ Clamps for Rubber Protective Joint Boots, Tensioning ]

12 - Locking Plate

13 - Bolt

Pre-tightening specification: 10 Nm and diagonally

Tightening specification M8: 40 Nm and diagonally

Tightening specification M10: 70 Nm and diagonally

Always replace if removed.

14 - Locking Ring

Replace

Removing and installing using (VW 161 A) => [ Removing securing ring ]

15 - Gasket

Bonding surface on CV joint must be free of grease and oil!

16 - Inner CV joint

Replace only as complete unit.

Checking, refer to => [ Inner CV Joint, Checking ] Inner CV Joint, Checking

Removing, refer to => [ Pressing On Inner CV Joint ]

Grease => table, page

Installing, refer to => [ Pressing On Inner CV Joint ]

When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.

17 - Plate Spring

Installed position, refer to => [ Installed Location of Spring Washer on Inner Joint ]

Drive Axle, Disassembling and Assembling

Disassembling Outer CV Joint





- Remove the CV joint from the drive axle by hitting it with a light alloy hammer.

Installed location of spring washer and thrust washer on outer joint.





1 - Plate Spring

2 - Thrust Ring

Outer CV Joint, Installing






- Before installing CV joint or triple roller star, splines - A - must be lightly coated with grease used in joint.

- Install old drive shaft bolt in joint as shown in the illustration.






- Drive joint onto shaft with plastic hammer until circlip engages.

Inner CV joint, disassembling and assembling

Removing securing ring





Drive Protective Joint Boot Cap under with a Brass or Copper Drift





Removing the Inner CV Joint





Assembling the CV Joint

Installed Location of Spring Washer on Inner Joint





Pressing On Inner CV Joint





- Before installing CV joint or triple roller star, splines - A - must be lightly coated with grease used in joint.






Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.

- Install circlip






- Apply sealant on the - hatched surface - on the clean surface on the inside of the cap. Refer to the Parts Catalog. Sealant bead: unbroken, 2 to 3 mm diameter Skirt area around inner holes - arrow -.






- Use sealant Parts Catalog.

- Slide joint protective boot onto drive shaft.

Drive shaft, protective joint boot and cap contact surfaces must be free of grease.

Make sure you do not damage the sealant bead.

- Using screws - arrows -, align protective boot and cap with screw holes.






It must be aligned exactly because it cannot be aligned after driving on.

- Drive off protective boot with cap using plastic hammer.

- Clear away leaking sealing immediately.

Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning





- Position pliers V.A.G 1682 as shown in illustration. When doing this, make sure that edges of clamping pliers are seated in corners - arrows B - of clamp.

- Tighten the hose clamp by turning spindle - A - using a torque wrench (do not tilt clamping pliers).

Tightening Specifications: 20 Nm

Be sure thread of spindle in clamping pliers moves freely. Grease with MOS2 grease, if necessary.

If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.

Clamps for Rubber Protective Joint Boots, Tensioning