Drive Axle With Inner Triple Roller Joint, Servicing
Drive axle with inner triple roller joint, servicing
Special tools, testers and auxiliary items required
^ CV joint boot clamp tool V.A.G 1682
^ Pliers 3340
^ Thrust plate VW402
^ Punch VW 411 I
^ Thrust disc VW 412
^ Tube 37 mm dia. VW 416b
^ Sleeve press tool VW522
^ Torque wrench V.A.G 1332 (measuring range: 5 to 50 Nm)
Grease quantities and types
Outer joints are packed with grease G 000 603:
Inner triple roller joints are packed with grease G 000 605:
Regrease joint if required when replacing the boot.
1 - Outer constant velocity (CV) joint
^ Replace only as complete unit
^ Removing
^ Installing and
^ Greasing
^ Checking Outer Constant Velocity (CV) joint, checking
2 - Hex bolt
^ Always replace if removed
Tightening torque
Observe instructions for removing and installing
3 - Outer constant velocity (CV) joint
^ Replace only as complete unit
^ Removing
^ Installing: drive onto shaft with plastic hammer until compressed circlip seats
^ Greasing
^ Checking Outer Constant Velocity (CV) joint,
4 - Self-locking 12-point nut
5 - Axle shaft
6 - Boot for triple roller star
7 - Hose clamp
8 - Socket-head bolt
Initial tightening torque: 10 Nm
Tightening torque: 70 Nm
9 - Cover
10 - Triple roller star
Chamfer - arrow - faces toward drive axle splines
^ Rollers are not removable
11 - Circlip
^ Replace
^ Insert in groove on shaft
12 - O-ring
^ Always replace
13 - Cover
^ Always replace
14 - Hose clamp
^ Always replace
^ Tightening
15 - CV Boot
^ Check for tears and scuffing
^ Material: Hytrel (polyelastomer)
16 - Hose clamp
^ Always replace
^ Tightening
17 - Convex washer
^ Installation position
18 - Spacer ring (plastic)
^ Installation position
19 - Circlip
^ Always replace
^ Insert in groove on shaft
Removing outer constant velocity (CV) joint
- Drive joint off axle shaft with a firm blow from an aluminum hammer.
Venting CV boot
The CV joint boot is often squashed when it is installed on the CV joint body. This creates a partial vacuum inside the boot which draws in a fold - arrow - while driving. For this reason, vent the boot to equalize pressure after installation by briefly lifting the lip at the small-diameter end.
Tightening hose clamps on outer CV joint
- Apply pliers V.A.G 1682 as shown. Make sure that the jaws of the pliers seat in the ends of the hose clamp - arrows B -.
- Tighten hose clamp by turning spindle with torque wrench (keep pliers straight).
Note:
^ Due to the hard material of the CV joint boot (as opposed to rubber), a stainless steel hose clamp is required; this can only be tightened using CV joint boot clamp tool V.A.G1682.
^ Tightening torque: 25 Nm.
^ Use torque wrench with 5 to 50 Nm range (e.g. V.A.G1331).
^ Make sure thread of spindle on pliers moves freely. Lubricate with MoS2 grease if necessary.
^ If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clamp with the specified tightening torque.
Tightening hose clamp at small diameter of boot
Installation position of spacer ring and convex washer
1 - Convex washer
2 - Spacer ring (plastic)
Disassembling and assembling inner triple roller star
Disassembling
- Bend open retaining tabs slightly and pry off cover.
- Mark positions of parts 1 through 3 in relation to each other before disassembling.
The joint may be noisy if these parts are not marked and reinstalled in their original positions.
Use a waterproof felt-tip pen for marking.
- Remove rubber ring - arrow - from groove.
1 - Joint body
2 - Triple roller star
3 - Drive axle
Note: The rollers must not be pressed off the triple roller star
- Remove circlip.
- Open hose clamp.
- Cut open joint boot and remove from shaft.
Note: The rollers on the triple roller star must not be pressed off or damaged.
- Insert axle shaft in press.
- Hold axle shaft, then press triple roller star off axle shaft.
- Pull joint body off shaft.
- Clean shaft and joint body.
Assembling
- Clamp axle shaft in vise using soft jaws.
- Push new boot onto shaft.
- Push joint body onto shaft.
Installing triple roller star
Chamfer on spider faces toward shaft and is used as an assembly aid.
- Place triple roller spider onto shaft as per markings and drive home onto stop.
- Install new circlip; make sure correct seating.
- Grease joint.
- Slide joint body over rollers and hold in position.
- Install joint boot.
- Install hose clamp.
- Insert O-ring - arrow - into groove.
- Install cover and bend down retaining tabs.