Drive Axle With Inner CV Joint (100 mm Diameter), Servicing

Drive axle with inner constant velocity joint (100 mm diameter), servicing





Grease quantities and types
Constant velocity joints are filled with lubricating grease G 000 603
Re-grease joint if boot is replaced.





1. Cover
^ Knock out carefully with mandrel - Go to Fig. 3
^ Always replace
^ Apply D 454 300 A2 to sealing surface before installing to constant velocity joint - Go to Fig. 6, Aligning cover with bolt holes
2. Circlip
^ Use commercially available circlip pliers for extraction and installation
3. Inner constant velocity joint
^ OD: 108 mm
^ Replace only as complete assembly
^ Bonding surfaces must be free of oil and grease
4. Boot for inner constant velocity joint with cap
^ With vent hole
^ Knock off cap carefully using mandrel
^ Always replace
^ If damaged, check inner constant velocity joint
^ Apply D 454 300 A2 to sealing surface before installing to constant velocity joint - Go to Fig. 6, Aligning cover with bolt holes
^ Sealing surfaces of drive axle boot must be free of grease during assembly
5. Drive axle
6. Boot for outer constant velocity joint
^ Without vent hole
^ Check for cracks and abrasion; replace if necessary
^ If damaged check outer constant velocity joint
^ Sealing surfaces of boot to drive axle/joint must be free of grease during assembly
7. Clamp
^ Always replace
^ Tightening - Go to Fig. 2
8. Circlip
^ Insert in shaft groove
9. Outer constant velocity joint
^ OD: 98 mm
^ Replace only as complete assembly
^ Driving in - Go to Fig. 1
^ Installing: Knock onto shaft with plastic hammer until installed circlip springs out.
^ When threaded in circlip must lie in chamfer of joint; guide with pliers if necessary.





Fig. 1 Pressing off outer constant velocity joint
- Clamp drive axle with soft jaws in vise.
- Release clip and draw boot back.
- Knock constant velocity joint off drive axle with mandrel -A-.
Mandrel must be positioned precisely at star of constant velocity joint.

Driving in joint
- Knock onto shaft with plastic hammer until circlip engages.





Fig. 2 Tensioning clamp





Fig. 3 Driving off inner joint cover





Fig. 4 Pressing off inner constant velocity joint
- Disengage circlip.
- Use mandrel to knock off boot.

Note: Support ball hub with plate -VW402-.





Fig. 5 Pressing on inner constant velocity joint
- Press on joint as far as it will go.
Use pressure piece VW412.
- Engage circlip.

Note: Position ball hub with inside diameter chamfer (splines) on drive axle.





Fig. 6 Coating sealing surface of cover or cap with D 454 300 A2
- Apply sealant -shaded area- to clean surface of cover or cap.
Sealant bead: uninterrupted, 2 to 3 mm diameter
Route around inside of holes -arrow-.
- Align cover and cap with bolt holes and knock or press onto joint.
- Wipe off excess sealant.