Rear Drive Axle With 108 mm Dia. Inner Constant Velocity Joint
Driveshaft with constant velocity inner joint (diameter 108 mm), servicing
Special tools, testers and auxiliary items required
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Punch VW 409
^ Punch VW 412
^ Support sleeve VW 522
^ Clamp 40-204 A
^ Assembly tool T10065/4
Grease quantity and type
Constant velocity joints are packed with grease G 000 603:
Grease joint again when replacing protective joint boot.
1 - Cover
^ Carefully drive off using a drift
^ Always replace
^ Coat sealing surface with D 454 300 A2 before installing on constant velocity joint
^ Align cover to screw holes
2 - Circlip
^ Remove and install with commercially-available circlip pliers
^ Always replace
3 - Inner CV joint with protective boot cap
^ Exterior diameter: 108 mm
^ Replace only as a unit
^ Pressing off
^ Pressing on
^ Greasing
^ Adhesive surface must be free of oil and grease
^ When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in joint.
4 - Backing plate
5 - Multi-point socket head bolt
^ Torque specifications:
Screw M 8: 40 Nm
Screw M10: 65 Nm
6 - Clamp
^ Always replace
^ Tensioning
7 - Protective boot for inner constant velocity joint
^ With vent hole
^ Check for tears and chafing; replace if necessary
^ In case of damage, check inner constant velocity joint
^ Protective boot/drive axle/cap sealing surfaces must be free of grease at installation
8 - Axle shaft
9 - Outer constant velocity protective joint boot
^ Exterior diameter: 88 mm
^ Without ventilation bore
^ Check for tears and chafing; replace if necessary
^ In case of damage, check outer constant velocity joint Outer constant velocity (CV) joint, checking
^ Protective boot/drive axle/joint sealing surfaces must be free of grease at installation
10 - Clamp
^ Always replace
^ Tensioning
11 - Circlip
^ Always replace
^ Insert in shaft groove
12 - Outer constant velocity joint
^ Replace only as a unit
^ Driving off
^ Installing: Drive onto shaft using plastic hammer until compressed circlip seats.
^ Circlip must lie in joint chamfer when guiding in, guide with pliers if necessary.
^ Greasing
^ When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in joint.
13 - Collar bolt
^ Always replace
Pressing off inner constant velocity joint
- Rebound circlip
- Drive off protective boot with drift.
Note:
^ Cap - A - must not be supported on thrust plate VW 401. Use segments T10065/4 as spacers.
Pressing on inner constant velocity joint
- Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
- Press on joint until stop.
- Insert circlip.
Note:
^ Position ball hub with chamfer on inner diameter (splines) on driveshaft.