Constant Velocity Joint Boot: Service and Repair

1. Drive axle with triple-rotor joint
- Supplied as replacement part with boot, item 3 below, and grease
- Lubricate with 140 grams (4.9 oz) of grease, Part No. G 000 605 or equivalent
- When replacing boot, item 3 in illustration below, grease joint again if necessary
2. Clamp
- Always replace
- Tightening, refer to Fig. 1, below.
3. Inner joint boot
- Check for cracks and abrasion
- To replace, press off outer CV joint
- When installing over splined shaft, lightly grease bead on shaft and carefully slide into position using VAG 1474/5 wedge, refer to Fig. 4, below.
4. Clamp
- Always replace
- Tightening, refer to Fig. 1, below.
5. Outer joint boot
- Check for cracks and abrasion
- Before tightening small clamp, ventilate briefly, refer to Fig. 3, below.
6. Clamp
- Always replace
- Tightening, refer to Fig. 1, below.
7. Spring washer
- Installation, refer to Fig. 5, below.
8. Spacer
- Installation, refer to Fig. 5, below.
9. Circlip
- Always replace
- Installation, refer to Fig. 5, below.
- During assembly, install in groove on shaft (not visible with joint installed)
10. Outer CV joint
- Replace as complete unit only
- Pressing off, refer to Fig. 2, below.
- Installing: drive joint onto shaft with soft-faced hammer until circlip engages
- Greasing
- Lubricate with 120 grams (4.7 oz) of grease
- Proportions:
Joint: 80 g (3.2 oz)
Boot: 40 g (1.6 oz)

Fig. 1 Tightening clamp:

Fig. 1 Tightening clamp

Fig. 2 Pressing off outer CV joint:

Fig. 2 Pressing off outer CV joint
- Clamp drive axle in vise with jaw covers.
- Remove clamps.
- Push back joint boot.
- Thread in special tool 3207 (16 mm thread) until CV joint is pressed off splined shaft.

Fig. 3 Ventilating CV boot:

Fig. 3 Ventilating boot
- Attaching the boot to the outer body of the joint frequently requires compressing or squeezing the boot. This can leave too little air inside the boot, which may cause a crease to develop (arrow).
- For this reason, after installing the boot, ventilate it briefly by letting some air in at the small diameter end to restore the correct shape.

Fig. 4 Pushing joint boot over bead on splined shaft:

Fig. 4 Pushing joint boot over bead on splined shaft

Fig. 5 Installation of circlip, spacer and spring washer:

Fig. 5 Installation of circlip, spacer and spring washer
1. Circlip
2. Spacer
3. Spring washer