Drive Axle With Constant Velocity (CV) Joint, Servicing
Drive axle with Constant Velocity (CV) joint, servicing
Grease quantities and types
Note: Grease CV joint with G 000 603 grease:
When replacing CV boot add more grease to joint, if necessary.
1. Snap ring
^ Always replace
^ Remove and install using VW161 a
2. Gasket
^ Replace, pull off protective foil and bond in joint.
3. Inner Constant Velocity (CV) joint
^ Outside diameter is 100 or 108 mm, depending on engine/transmission combination
^ Replace only as complete unit
^ Pressing off Fig. 3
^ Pressing on Fig. 4
4. Drive axle shaft (tubular)
5. Clamp
^ Always replace
6. CV boot
^ Check for tears and scuffing
^ Before tightening clamp, briefly raise CV boot to allow pressure to equalize refer to Fig. 6
7. Clamp
^ Always replace
^ Tightening refer to Fig. 1 and refer to Fig. 6
8. Dished washer
^ Large diameter (concave side) rests against thrust washer
^ Installation position Fig. 5
9. Thrust washer
^ Installation position Fig. 5
10. Snap ring Always replace insert in groove on shaft
11. Outer CV Joint
^ Replace only as complete unit
^ Removing refer to Fig. 2
^ Installing: Use plastic hammer to drive onto shaft until snap ring snaps into ring groove of Constant Velocity (CV) joint.
12. Hex bolt
^ Always replace after disassembly
Tightening torques: Bolt M 14:
^ 115 Nm plus additional 180° (1/2 -turn)
Bolt M 16:
^ 190 Nm plus additional 180° (1/2 -turn)
Observe assembly notes when removing
Observe assembly notes when installing
13. Socket-head bolt
^ M8 x 48: 40 Nm
^ M10 x 48: 70 Nm
14. Backing plate
15. CV boot for Inner Constant Velocity (CV) joint
^ Check for tears and scuffing
^ Drive off using drift
^ Spread D 454 300 A2 on sealing surface before mounting on Constant Velocity (CV) joint
Special tools and equipment
^ V.A.G 1275 hose clamp pliers
^ 3207 Pressing screw
^ VW411 Punch
^ VW 161 A snap ring pliers
^ VW 401/402 pressure plates
^ VW412 punch
^ VW 522 sleeve press tool
^ 40-204 A press block
^ VAG1682 clamping pliers
^ 3340 pliers
Rubber CV boot are clamped on with VAG1275 pliers.
The Instructions for Fig.1 apply only to stainless steel tensioning clamps!
Fig. 1 Tension the clamp on outer joint
^ Apply VAG1 682 CV boot clamping pliers as shown in figure. Be sure that edges of clamping pliers are seated in corners (arrows -B-) of hose clamp.
^ Tighten hose clamp by turning spindle with a torque wrench (do not tilt clamping pliers).
Note:
^ Tightening torque: 20 Nm.
^ Use torque wrench with adjustment range from 5 to 50 Nm (e.g. VAG1331).
^ Be sure thread of spindle in clamping pliers moves freely. Grease with MoS 2 grease, if necessary.
^ If it does not move freely, e.g. due to dirt in thread, the required clamp tension will not be achieved at the specified torque.
Fig. 2 Pressing off outside Constant Velocity (CV) joint
^ Clamp drive axle in vise with protective pads.
^ Take off hose clamp and push back boot
^ Screw special tool with M 16 / M 14 thread design into joint bolt until Constant Velocity (CV) joint is pressed off drive axle.
Fig. 3 Pressing off Inner constant velocity joint
Note:
^ First, use a drift to drive off boot.
^ Support ball hub.
Fig. 4 Pressing on Inner constant velocity joint
^ Press on joint until it stops.
^ Install lock ring.
Note: Chamfer on inner diameter of ball hub (splines) must face contact shoulder of drive axle.
Fig. 5 Installed position of spacer ring and dished washer (wheel side)
1. Dished washer
2. Spacer ring (plastic)
Fig. 6 Venting CV boot
Only affects rubber CV boots
The CV boot is frequently pressed in when placed on the CV joint body. This creates a vacuum in the CV boot, which pulls a fold inward when the car is driven (arrow). After CV boot is installed, briefly ventilate it at small diameter, to allow pressure to equalize.