Inner CV Joint, 108 mm Diameter, Servicing

Inner CV Joint, 108 mm Diameter, Servicing

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 412)

• Clamp (40 - 204 A)

• Support Sleeve (VW 516)

• Punch (VW 409)

Inner CV joint, removing

- Drive axle, clamping in vise.

Use protective vise covers for this.

- Drive cover down with copper or brass drift.





- Remove circlip.





- Remove joint grease and mark location of CV joint to drive axle.

- Clamp drive axle in vise at CV joint, as shown in illustration.

- A 2nd technician must hold drive axle horizontally so that CV joint is not damaged.

- Bend edge - arrow - of cap up slightly with small flat chisel.





- Drive cap down with copper or brass drift

- Press CV joint off of drive axle.





- Remove protective boot with cap.

Inner CV joint, installing

- Apply sealant D 454 300 A2 - hatched surface - to clean surface on inner side of protective boot cover or cap. Sealant bead: unbroken, 2 to 3 mm, dia. skirt area around inner holes - arrow -.





Protective boot and cap contact surfaces must be free of grease!

- Slide new protective booth with cap onto drive axle.

- Press 85 g joint grease into boot.

- Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.





- Secure CV joint from coming apart, e.g. with adhesive tape - arrow -.





- Press off CV joint.

• Position ball hub with chamfer on inner diameter (splines) on drive axle.

Use special tool shown in illustration.

Press block 40-204 A and clamping surfaces on drive axle must be free of grease.

- Install circlip

- Press 35 g joint grease into joint through ball races.

- Using bolts - arrows -, align protective boot and cap with bolt holes.





It must be aligned exactly because it cannot be aligned after driving on.

- Drive off protective boot with cap using plastic hammer.

- Clear away leaking sealing immediately.

- Align new cover with bolts - arrows - to bolt holes.





It must be aligned exactly because it cannot be aligned after driving on.

- Drive cover on with a plastic hammer.

- Clear away leaking sealing immediately.