Service Notes

Drive axle with constant velocity joint, assembly
Grease quantity and type





Constant velocity joints are packed with grease Part NO. G 000 603:
Regrease the joint, if necessary, when replacing the protective boot.





1. Outer constant velocity joint
^ Only replace complete
^ Removing refer to Fig. 1
^ Installing: drive onto shaft to stop with plastic-headed hammer
2. Bolt
^ Always replace each time after removing
^ 120 Nm (89 ft. lbs.) and turn 180° further

WARNING: The drive axle bolt must be loosened or tightened only with the vehicle standing on its wheels.

3. Protective boot
^ Check for tears and chafing
4. Clamp
^ Always replace
5. Multi-point socket head bolt
^ 40 Nm (30 ft. lbs.)
^ M8x48
6. Plate
7. Protective boot for inner constant velocity joint
^ Check for tears and chafing
^ Drive off with drift
^ Before installing on constant velocity joint, coat sealing surface with D-3
8. Dished washer
^ Not applicable
9. Inner constant velocity joint
^ Only replace complete
^ Pressing off refer to Fig. 2
^ Pressing on refer to Fig. 3
10. Gasket
^ Replacing: pull off protective foil and stick onto joint.
11. Circlip
^ Always replace
^ Remove and install with VW 161a
12. Drive shaft
13. Dished washer
^ Outer diameter (concave side) contacts thrust washer
14. Thrust washer
15. Circlip
^ Always replace
^ Insert in shaft groove





Fig. 1 Pressing off outer constant velocity joint
- Clamp drive axle in vise using protective jaw covers.
- Remove clamp and slide back boot.
- Install M14 threaded section into joint until constant velocity joint is pressed off drive axle.





Fig. 2 Pressing off inner constant velocity joint

Note:
^ First drive off boot with a drift
^ Support the ball hub





Fig. 3 Pressing on inner constant velocity joint
- Press joint on up to stop.
- Install circlip.

Note: The chamfer on the inner diameter of the ball hub (splines) must face the contact shoulder on the drive axle.