Drive Axle With 90 mm Outer CV Joint, Servicing
Drive Axle with 90 mm Outer CV Joint, Servicing
Filling the Joints with Grease
• Grease joint again when replacing protective joint boot.
1 - Outer CV Joint
• Replace only as complete unit.
• Checking, refer to => [ Outer CV Joint, Checking ] Outer CV Joint, Checking
• Removing => [ 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.
2 - Bolt
• 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 Between Drive Axle and Wheel Hub, Loosening and Tightening ] Twelve-Point Bolt With Ribs Between Drive Axle and Wheel Hub, Loosening and Tightening.
• Twelve-point bolt without ribs, refer to => [ Twelve-Point Bolt without Ribs Between Drive Axle and Wheel Hub, Loosening and Tightening ] Twelve-Point Bolt Without Ribs Between Drive Axle and Wheel Hub, Loosening and Tightening
• Different versions, allocation, refer to the Parts Catalog
• Always replace if removed.
• Before installing, clean the threads in the CV joint with a tap.
3 - Profile Shaft
4 - Clamp
• Replace
• Tensioning, refer to => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ] y or => [ Clamps for rubber Protective Joint Boots, Tensioning ]
5 - CV Boot for outer CV joint
• Without vent hole
• Check for tears and scuffing
6 - Clamp
• Replace
• Tensioning, refer to => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ] or => [ Clamps for rubber Protective Joint Boots, Tensioning ]
7 - Plate Spring
• Installed position, refer to => [ Installed Location of Spring Washer and Thrust Washer on Outer Joint ]
8 - Spacer Ring (plastic)
• Installed position, refer to => [ Installed Location of Spring Washer and Thrust Washer on Outer Joint ]
9 - Locking Ring
• Replace
• Insert in shaft groove
10 - Protective Boot for Inner CV Joint
• Without vent hole
• Check for tears and scuffing
• Drive off CV joint using drift
• Coat the sealing surface with D 454 300 A2 before installing it on the CV joint
11 - Clamp
• Replace
• Tensioning, refer to => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ] or => [ Clamps for rubber Protective Joint Boots, Tensioning ]
12 - Locking Plate
13 - Internal Multi-Point Bolt
• first tighten diagonally to 10 Nm, then tighten diagonally again to the tightening specification
• Tightening specification M8: 40 Nm and diagonally
• Tightening specification M10: 70 Nm and diagonally
• Always replace if removed.
14 - Locking Ring
• Replace
• Removing and installing using (VW 161 A) => [ Removing Securing Ring ]
15 - Gasket
• Bonding surface on CV joint must be free of grease and oil!
16 - 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.
17 - Plate Spring
• Installed position => [ Installed Location of Spring Washer on Inner Joint ]
Drive Axle, Disassembling and Assembling
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Punch (VW 411)
• Sleeve (VW 416 B)
• Thrust pad (VW 447 H)
Special tools, testers and auxiliary items required
• Circlip pliers (VW 161 A)
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1332)
• CV joint boot clamp tool (V.A.G 1682)
• Assembly tool (T10065)
Outer CV Joint, Disassembling and Assembling
Disassembling Outer CV Joint
- Remove the CV joint from the drive axle by hitting it with a light alloy hammer.
Installed Location of Spring Washer and Thrust Washer on Outer Joint
1 - Plate Spring
2 - Thrust Ring
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
Removing Securing Ring
Drive Protective Joint Boot Cap Under with a Brass or Copper Drift
Removing the Inner CV Joint
Assembling the CV joint
Installed Location of Spring Washer on Inner Joint
Pressing On Inner CV Joint
- Before installing CV joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
- Pressing on inner CV joint
• Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.
- Install circlip
- Apply sealant on the - hatched surface - on the clean surface on the inside of the cap. Refer to the => Parts Catalog. Sealant bead: unbroken, 2 to 3 mm diameter Skirt area around inner holes - arrow -.
- Use sealant => Parts Catalog.
- Slide joint protective boot onto drive shaft.
Drive shaft, protective joint boot and cap contact surfaces must be free of grease.
Make sure you do not damage the sealant bead.
- Using screws - arrows -, align protective boot and cap with screw 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.
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 e.g. 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
