Constant Velocity Joint: Service and Repair

Fig. 1 Disassembled view of drive axle:

OUTER JOINT

1. Remove drive axle as outlined previously.
2. Secure drive axle in a suitable vise.
3. Remove outer joint boot retaining clamp, then pull boot toward inner joint, Fig. 1.

Fig. 2 Outer joint circlip:

4. Spread ears of circlip inside hub and tap on front of shaft to drive joint off shaft, Fig. 2.
5. Mark ball hub in relation to cage and housing, then turn cage until large openings are level with outer housing. Remove cage together with hub.

Fig. 3 Removing hub from ball cage:

6. Position hub until one segment can be pushed into larger opening of cage, then remove hub from cage, Fig. 3. Always replace hub, outer ring, ball cage and balls together, since each belong to one specific tolerance group.

Fig. 4 Positioning dished and thrust washers. Outer joint:

7. Reverse procedure to install. Ensure dished side of dished washer and convex side of thrust washer face toward joint, Fig. 4.

Fig. 5 Removing inner joint:

INNER JOINT

1. Compress circlip with pliers and remove from joint.
2. Using drift and hammer, carefully drive protective cap off joint.
3. Using tools VW 408a & VW 402 or equivalent, remove joint from drive axle, Fig. 5.
4. Pivot ball hub and cage and remove from outer ring, then press balls out of cage.
5. Align grooves, then remove ball hub from cage.

Fig. 6 Positioning inner joint dished washer:

6. Reverse procedure to install, ensuring:
a. Chamfer on inside diameter of ball hub faces shoulder on drive axle.
b. Wide ball groove in outer ring and narrow groove in hub are together on one side.
c. Dished side of dished washer faces splined area of drive axle, Fig. 6.