Rear Drive Axle with 100 mm Dia. Inner Constant Velocity Joint
Drive axle with constant velocity inner joint (diameter 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
^ Hose clamp pliers V.A.G 1275
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 constant velocity joint
^ Exterior diameter: 100 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 - Protective boot for inner CV joint with cap
^ With vent hole
^ Carefully drive off cap with drift
^ Always replace
^ In case of damage, check inner constant velocity joint
^ Coat sealing surface with D 454 300 A2 before installing on constant velocity joint
^ Align cover to screw holes
^ Protective boot/drive axle sealing surfaces must be free of grease at installation
7 - Axle shaft
8 - Outer constant velocity protective joint boot
^ Without ventilation bore
^ Check for tears and chafing; replace if necessary
^ In case of damage, check outer constant velocity joint
^ Protective boot/drive axle/joint sealing surfaces must be free of grease at installation
9 - Clamp
^ Always replace
^ Tensioning
10 - Circlip
^ Always replace
^ Insert in shaft groove
11 - Outer constant velocity joint
^ Exterior diameter: 88 mm
^ 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.
12 - Collar bolt
^ Always replace
Pressing off outer constant velocity joint
- Secure drive shaft with protective covers in vise clamp.
- Loosen clamp and turn back protective boot.
- Drive CV joint from drive axle using a drift - A -.
Drift must be placed precisely on star of CV joint.
Driving joint on
- Drive onto shaft with plastic hammer until securing ring engages.
Tighten clamp
Drive off cover for inner joint
Pressing off inner constant velocity joint
- Rebound circlip
- Drive off protective boot with drift.
Note:
^ Support ball hub with Thrust Plate VW402.
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.
Use support sleeve VW 522
- Insert circlip.
Note:
^ Position ball hub with chamfer on inner diameter (splines) on drive axle.
Coat cover or cap sealing surface with D 454 300 A2
- Apply sealant - hatched surface - to clean cover or cap surface. Sealant bead: unbroken, dia. 2 to 3 mm, skirt area around inner holes - arrow -.
- Align cover and cap to screw holes and drive or press onto joint.
- Clear away leaking sealant immediately.