Drive Axle With Inner CV Joint, Attached With Inner Splines
Drive Axle with Inner CV Joint, Attached with Inner Splines
Filling Joints with Grease
1 Bolt
• Different versions. Allocation, refer to the Electronic Parts Catalog (ETKA).
• Always replace if removed.
• Hex bolt: 200 Nm +180° turn. Loosening and tightening, refer to => [ Drive Axle Hex Bolt Connection, Loosening and Tightening ] Description and Operation.
• Twelve-point bolt with ribs: 70 Nm +90° turn. Loosening and tightening, refer to => [ Drive Axle Twelve-Point Bolt with Ribs, Loosening and Tightening ] Drive Axle Twelve-Point Bolt With Ribs, Loosening and Tightening.
• Twelve-point bolt without ribs: 200 Nm +180° turn. Loosening and tightening, refer to => [ Drive Axle Twelve-Point Bolt without Ribs, Loosening and Tightening ] Drive Axle Twelve-Point Bolt Without Ribs, Loosening and Tightening.
• Before installing, clean the threads in the CV joint with a tap.
2 Outer CV Joint
• Replace only as complete unit.
• Divide the grease between the ball paths.
• Installing: Drive onto shaft until impact using plastic hammer.
• Checking, refer to => [ Outer CV Joint, Checking ] Outer CV Joint, Checking.
3 Securing Ring
• Always replace if removed.
• Insert in shaft groove.
4 Clamp
• Always replace if removed.
5 Protective Boot
• Check for tears and scuffing.
• Material: Hytrel (Polyelastomer).
6 Clamp
• Always replace if removed.
• Tensioning.
7 Drive Axle
8 Clamp
• Always replace if removed.
• Tensioning.
9 CV Joint Protective Boot
• Material: Hytrel (Polyelastomer).
• Check for tears and scuffing.
10 Securing Ring
• Always replace if removed.
• Insert in shaft groove.
11 Clamp
• Always replace if removed.
• Tensioning.
12 CV Joint
• Replace only as complete unit.
• Removing.
• Divide the grease between the ball paths.
• Installing: Drive onto shaft until impact using plastic hammer.
13 Protective Cap
• Removing.
• Installing.
Outer CV Joint, Removing
- Secure the drive axle with protective covers in a vise clamp.
- Open both clamping sleeves and remove protective joint boot from outer joint.
- Strike a copper or brass drift - A - on CV joint inner race with a hammer.
- Remove joint and protective joint boot.
Installing the Outer Joint
• Joints and protective joint boots must be free of grease.
- Replace the circlip - 1 -.
- Slide on the small clamp with the protective boot and position the protective boot on the drive axle.
- Position CV boot in outer groove - arrow B -.
• Inner groove - arrow A - must remain visible "identification groove" (for correct installation of CV boot).
- Add approximately 70% of the grease to the inner joint.
- Before installing joint piece, splines - A - must be lightly coated with grease used in joint.
- Slide on CV joint up to sealing ring.
- Align sealing ring at center with opening upward see - arrows -.
- Screw old drive axle bolt into joint as shown in the illustration.
- Drive joint onto drive axle with plastic hammer until circlip engages.
- Add the rest of the grease into the joint on the boot side.
- Slide the protective boot onto the joint.
- Bleed protective joint boot.
- Make sure the protective boot is seated on the joint correctly.
- Protective joint boot must fit in groove and on joint contour.
- Tension clamps on outer joint.
Removing the Inner CV Joint
- Secure the drive axle with protective covers in a vise clamp.
- Fold back boot.
- Remove the CV joint from the drive axle using a drift - A -.
Drive must be applied exactly on star of CV joint.
Installing the Inner CV Joint
- Drive onto shaft with plastic hammer until securing ring engages.
Mount and tension stainless steel clamp using clamping device (V.A.G 1682) as illustrated.
- Attach (V.A.G 1682) as shown in illustration. When doing this, make sure that edges of clamping pliers are seated in corners - arrows B - of clamp.
- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).
• A stainless steel clamp must be used due to the hardness of the CV boot material (compared to rubber). This clamp can only be tensioned using the (V.A.G 1682).
• Tightening specifications: 25 Nm.
• Use torque wrench - C - with adjustment range 5..50 Nm (for example (V.A.G 1331) ).
• Be sure thread of spindle - A - of clamp tool moves freely. Grease with MOS 2 grease if necessary.
• If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.
Removing the Cap from the CV Joint
1. Three arm extractor, for example (Kukko 45-2)
2. (VW 447 H)
Mounting the Cap onto the CV Joint
1. (T10243)
Mount the cap far enough onto the joint until the ridge - arrow A - fits into the groove - arrow B -.