Inner Constant Velocity Joint, 100 mm, ServicingCV

Inner Constant Velocity Joint, 100 mm, 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 522)

• Punch (VW 411)

• Press Piece (VW 434)

• Press Appliance (VW 459)

Inner CV joint, removing

- Drive axle, clamping in vise

Use protective vise covers for this.

- Pry off cap, e.g. with a screwdriver.





- Remove seal - arrow -





- Drive protective joint boot cap under with a brass or copper drift





Clamping sleeves must not be loosened.

- Remove circlip





- Press inner CV joint off of drive axle with special tool shown in illustration.





- Remove inner CV joint protective boot from drive axle.

Inner CV joint, installing

- Apply sealant - hatched surface - to clean surface on inner side of protective joint boot cap. Sealant bead: unbroken, 2 to 3 mm in dia. Skirt area around inner holes - arrow -.





- Use sealant D 454 300 A2 for this

- Slide joint protective boot onto drive axle.

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





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

- Press on joint until stop.





Chamfer on inner diameter of ball hub (splines) must face contact shoulder of 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





- Check circlip for correct seating.

Circlip must be replaced

- Apply 50 g joint grease in boot.

Make sure you do not damage the sealant bead.

- 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.

- Apply 30 g joint grease in CV joint through ball paths.

- Grease seal contact surface - arrow -.





- Remove adhesive foil from seal and adhere to CV joint.

- Align new cover with bolt holes.

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

- Press cover on with special tool shown in illustration.





- Position protective joint boot between - arrows -.