Drive Axle With 100 mm Diameter Inner CV Joint
Drive Axle with 100 mm Diameter 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)
• Thrust Piece (T10243)
Filling Joints with Grease
1 Bolt
• Always replace if removed.
• Different versions, allocation, refer to the Parts Catalog
• 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
• Before installing, clean the threads in the CV joint with a tap.
2 Outer CV joint
• Replace only as complete unit.
• Removing, refer to => [ Outer CV Joint, Removing ]
• Divide the grease between the ball paths
• Installing: Drive onto shaft until impact using plastic hammer
• Checking, refer to => [ Outer CV Joint, Checking ] Outer CV Joint, Checking
3 Locking Ring
• Always replace if removed.
• Insert in shaft groove
4 Clamp
• Always replace if removed.
• Tensioning, refer to => [ Mount and Tension Stainless Steel Clamp Using as illustrated. ]
5 Protective boot
• Check for tears and scuffing
• Material: Hytrel (Polyelastomer)
6 Clamp
• Always replace if removed.
• Tensioning, refer to => [ Mount and Tension Stainless Steel Clamp Using as illustrated. ]
7 Drive Axle
8 Clamp
• Always replace if removed.
• Tensioning, refer to => [ Mount and Tension Stainless Steel Clamp Using as illustrated. ]
9 CV joint protective boot
• Material: Hytrel (Polyelastomer)
• Check for tears and scuffing
10 Locking Ring
• Always replace if removed.
• Insert in shaft groove
11 Clamp
• Always replace if removed.
• Tension in, refer to => [ Mount and Tension Stainless Steel Clamp Using as illustrated. ]
12 CV joint
• Replace only as complete unit.
• Removing, refer to => [ Removing the Inner CV Joint ]
• Divide the grease between the ball paths
• Installing: Drive onto shaft until impact using plastic hammer
13 Cap
• Remove, refer to => [ Removing the Cap from the CV Joint ]
• Installing, refer to => [ Mounting the Cap onto the CV Joint ]
Outer CV Joint, Removing
- Secure the drive axle with protective covers in a vise clamp.
- Open both clamping sleeves and remove protective joint boot from outer joint.
- Strike a copper or brass drift - A - on CV joint inner race with a hammer.
- Remove joint and protective joint boot.
Installing Outer Joint
Joints and protective joint boots must be free of grease.
- Replace the circlip - 1 -.
- Slide on the small clamp with the protective boot and position the protective boot on the drive axle.
- Position CV boot in outer groove - arrow B -.
Inner groove - arrow A - must remain visible "identification groove" (for correct installation of CV boot).
- Add approximately 70% of the grease to the inner joint. See the table.
- Before installing joint piece, splines - A - must be lightly coated with grease used in joint.
- Slide on CV joint up to sealing ring.
- Align sealing ring at center with opening upward - see arrows -.
- Screw old drive axle screw into joint as shown in the illustration.
- Drive joint onto drive axle with plastic hammer until circlip engages.
- Add the rest of the grease into the joint on the boot side.
- Slide the protective boot onto the joint.
- Bleed protective joint boot.
- Make sure the protective boot is seated on the joint correctly.
- Protective joint boot must fit in groove and on joint contour.
- Tension clamps on outer joint => [ Mount and Tension Stainless Steel Clamp Using as illustrated. ].
Removing the Inner CV Joint
- Secure the drive axle with protective covers in a vise clamp.
- Fold back boot.
- Remove the CV joint from the drive axle using a drift - A -.
Drive must be applied exactly on star of CV joint.
Installing Inner CV Joint
- Drive onto shaft with plastic hammer until securing ring engages.
Mount and Tension Stainless Steel Clamp Using (V.A.G 1682) as illustrated.
- Attach (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.
- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).
• A stainless steel clamp must be used due to the hardness of the CV boot material (compared to rubber). This clamp can only be tensioned using the (V.A.G 1682).
• Tightening Specifications: 25 Nm.
• Use torque wrench - C - with adjustment range 5..50 Nm (for example (V.A.G 1331) ).
• Be sure thread of spindle - A - of clamp tool moves freely. Grease with MOS 2 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.
Removing the Cap from the CV Joint
1. Three arm extractor, for example Kukko 45-2
2. (VW 447 H)
Mounting the Cap onto the CV Joint
1. (T10243)
Mount the cap far enough onto the joint until the ridge - arrow A - fits into the groove - arrow B -.