Drive Axle With 108 mm Inner CV Joint
Drive Axle with 108 mm Inner CV Joint
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Punch (VW 411)
• Tube 37 mm Diameter (VW 416 B)
• Thrust Pad (VW 447 H)
• Circlip Pliers (VW 161 A)
• Torque Wrench 5-50 Nm (V.A.G 1331)
• Torque Wrench 40-200 Nm (V.A.G 1332)
• CV Joint Boot Clamp Tool (V.A.G 1682)
• Assembly Tool (T10065)
Filling the Joints with Grease
• Grease joint again when replacing protective joint boot.
1 - Bolt
• Always replace if removed.
• Different versions, allocation, refer to the Parts Catalog
• Hex bolt = 200 Nm + 180° additional turn => [ Hex Bolt between Drive Axle and Wheel Hub, Loosening and Tightening ] Hex Bolt Between Drive Axle and Wheel Hub, Loosening and Tightening.
• Twelve-point bolt with ribs = 70 Nm + 90° additional turn, refer to => [ Twelve-Point Bolt with Ribs, Loosening and Tightening, Drive Axle to Wheel Hub ] Twelve-Point Bolt With Ribs, Loosening and Tightening, Drive Axle to Wheel Hub.
• Twelve-point bolt without ribs = 200 Nm +180° additional turn, loosening and tightening, refer to => [ Twelve-Point Bolt without Ribs, Loosening and Tightening, Drive Axle to Wheel Hub ] Twelve-Point Bolt Without Ribs, Loosening and Tightening, Drive Axle to Wheel Hub
• Before installing, clean the threads in the CV joint with a tap.
2 - Outer CV Joint
• Replace only as complete unit.
• Checking, refer to => [ Outer CV Joint, Checking ] Outer CV Joint, Checking
• Removing, refer to => [ Disassembling Outer CV Joint ]
• Grease => table, page
• Installing
• When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
3 - Locking Ring
• Replace
• Insert in shaft groove
4 - Spacer ring (plastic)
• Installed position, refer to => [ Location of Spacer Ring and Spring Washer on Outer Joint ]
5 - Plate Spring
• Installed position, refer to => [ Location of Spacer Ring and Spring Washer on Outer Joint ]
6 - Clamp
• Replace
• Tensioning, refer to => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ] or => [ Clamps for Rubber Protective Joint Boots, Tensioning ]
7 - CV Boot for Outer CV Joint
• Without vent hole
• Check for tears and scuffing
8 - Clamp
• Replace
• tensioning, refer to => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ] or => [ Clamps for Rubber Protective Joint Boots, Tensioning ]
9 - Profile shaft
10 - Clamp
• Replace
• Tensioning, refer to => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ] or => [ Clamps for Rubber Protective Joint Boots, Tensioning ]
11 - Protective boot for inner CV joint
• Check for tears and scuffing
12 - Bolt
• Pre-tightening specification: 10 Nm and diagonally
• Tightening specification M8: 40 Nm and diagonally
• Tightening specification M10: 70 Nm and diagonally
• Always replace if removed.
13 - Locking Plate
14 - Clamp
• Replace
• Tensioning, refer to => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ] or => [ Clamps for Rubber Protective Joint Boots, Tensioning ]
15 - Inner CV joint
• Replace only as complete unit.
• Checking, refer to => [ Inner CV Joint, Checking ] Inner CV Joint, Checking
• Removing, refer to => [ Removing the inner CV joint ]
• Grease => table, page
• Installing, refer to => [ Pressing on Inner CV Joint ]
• When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
16 - Locking Ring
• Replace
• Removing and installing using (VW 161 A) => [ Circlip, Removing and Installing ]
17 - Cover
• Replace
• Drive off CV joint using drift
• Apply sealant between the joint and the cover. Refer to the Parts Catalog, refer to => [ Coat the sealing surface on the cover with and then install it. ].
Drive Axle, Disassembling and Assembling
Disassembling Outer CV Joint
- Remove the CV joint from the drive axle by hitting it with a light alloy hammer.
Location of Spacer Ring and Spring Washer on Outer Joint
1 Plate Spring
2 Spacer ring (plastic)
Outer CV Joint, Installing
- Before installing CV joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
- Install old drive shaft bolt in joint as shown in the illustration.
- Drive joint onto shaft with plastic hammer until circlip engages.
Inner CV Joint, Disassembling and Assembling
Cover, Removing
- Drive cover down with copper or brass drift.
Circlip, Removing and Installing
Removing the inner CV joint
- Drive out CV joint boot with a drift.
- Support ball hub when pressing off.
Pressing on Inner CV Joint
- Before installing CV joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
- Press on joint until stop.
- Install circlip.
• Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.
Coat the sealing surface on the cover with sealant and then install it.
- Apply sealant - hatched area -to clean cover surface.
• Sealant bead: unbroken, 2 to 3 mm diameter Guide past inner hole area - arrow -
- 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.
- Wipe off any sealant leaking out.
Rubber Protective Joint Boot, Ventilating
The CV boot is frequently pressed in when placed on the CV joint body. This creates a vacuum in the CV boot, which pulls a fold inward when the car is driven - arrow -.
Therefore, observe the following:
- Before clamping the clamping sleeves, balance pressure by raising protective joint boot.
Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning
- Position pliers (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.
- Tighten the hose clamp by turning spindle - A - using a torque wrench (do not tilt clamping pliers).
• Tightening specifications: 20 Nm
• Be sure thread of spindle in clamping pliers moves freely. Grease with MOS2 grease, if necessary.
• If the thread is tight for example dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.
Clamps for Rubber Protective Joint Boots, Tensioning
