Drive Axle With 82 mm Outer CV Joint, Servicing
Drive Axle with 82 mm Outer CV Joint, Servicing
1 Outer CV Joint
• Replace only as complete unit.
• Removing, refer to => [ Outer CV Joint, Pressing Off ]
• Installing: Drive onto shaft until impact using plastic hammer
• Divide the grease evenly in the joint
• Checking, refer to => [ Outer CV Joint, Checking ] Outer CV Joint, Checking
2 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 Between Drive Axle and Wheel Hub, Loosening and Tightening ] Twelve-Point Bolt With Ribs Between Drive Axle and Wheel Hub, Loosening and Tightening.
• Twelve-point bolt without ribs, refer to => [ Twelve-Point Bolt without Ribs Between Drive Axle and Wheel Hub, Loosening and Tightening ] Twelve-Point Bolt Without Ribs Between Drive Axle and Wheel Hub, Loosening and Tightening
• Before installing, clean the threads in the CV joint with a tap.
3 Drive Axle
• Allocation, refer to the parts catalog.
4 Clamp
• Always replace if removed.
• Tensioning, refer to => [ Tensioning Clamp On Small Diameter ]
5 Protective Boot
• Check for tears and scuffing
• Material: Hytrel (Polyelastomer)
6 Clamp
• Always replace if removed.
• Tensioning, refer to => [ Tightening Hose Clamp On Outer Joint ]
7 Plate Spring
• with inner splines
• Installed position
8 Locking Ring
• Always replace if removed.
• Insert in shaft groove
9 CV Boot
• Material: Hytrel (Polyelastomer)
• Without vent hole
• Check for tears and scuffing
• Drive off CV joint using drift
• Before mounting onto CV joint, coat sealing surface using (D 454 300 A2)
10 Clamp
• Always replace if removed.
• Tensioning, refer to => [ Tensioning Clamp On Small Diameter ]
11 Locking Plate
12 Internal Multi-Point Bolt
• first tighten diagonally to 10 Nm, then tighten diagonally again to the tightening specification
• Tightening specification M8: 40 Nm and diagonally
• Tightening specification M10: 70 Nm and diagonally
• After disassembly, always replace bolts
13 Locking Ring
• Always replace if removed.
• Remove and install using snap ring pliers (VW 161 A)
14 Gasket
• Always replace if removed.
• Bonding surface on CV joint must be free of grease and oil!
15 Inner CV joint
• Replace only as complete unit.
• Divide the grease evenly in the joint
• Removing, refer to => [ Removing the Inner CV Joint ]
• Installing, refer to => [ Pressing On Inner CV Joint ]
• Checking, refer to => [ Inner CV Joint, Checking ] Inner CV Joint, Checking
16 Plate Spring
• with inner splines
• Installed position
Drive Axle, Disassembling and Assembling
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Punch (VW 411)
• Sleeve (VW 416 B)
• Thrust pad (VW 447 H)
Special tools, testers and auxiliary items required
• Circlip pliers (VW 161 A)
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1332)
• CV joint boot clamp tool (V.A.G 1682)
• Assembly tool (T10065)
Disassembling
Outer CV Joint, Pressing Off
- Secure the drive axle with protective covers in a vise clamp.
- Fold back boot.
- Drive CV joint from drive axle using a drift - A -.
Drift must be placed precisely on star of CV joint.
Driving joint on
- Drive onto shaft with plastic hammer until securing ring engages.
Removing the Inner CV Joint
- Press off CV from joint using drift.
- Remove securing ring.
- Remove both clamps, and push joint boot toward outer joint.
Assembling
Dished washer installation position, inner and outer joint
1. Plate Spring
- Press on joint until stop.
- Install lock ring.
Pressing On Inner CV Joint
• Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.
Tightening Hose Clamp On Outer Joint
- Attach CV joint boot clamp tool (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 clamp by turning the spindle using a torque wrench (do not tilt the pliers).
• 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 CV joint boot clamp tool (V.A.G 1682).
• Tightening Specifications: 25 Nm.
• Use torque wrench - C - with adjustment range 5..50 Nm (e.g. torque wrench (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.
Tensioning Clamp On Small Diameter
