Drive Axle With Constant Velocity Joint
Drive shaft with constant velocity joint, servicingSpecial tools, workshop equipment, test and measuring appliances and aux. items required
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 408 A Press tool
^ VW 411 Press tool
^ VW 447 H Press plate
^ VW 454 Press piece
Special tools, workshop equipment, test and measuring appliances and aux. items required
^ VW 161 A Circlip pliers
^ VAG 1331 Torque wrench
^ VAG 1332 Torque wrench
^ VAG 1682 Tension clamp
^ T10065 Assembly device
Grease quantity and type
Constant velocity joints are packed with grease G 000 603:
Regrease joint, if necessary, when replacing the protective boot.
1. Hex key head bolt, 25 Nm
2. Heat shield
3. Circlip
^ Always replace
^ Remove and install with VW 161 a
4. Gasket
^ Replacing. Pull off protective foil and stick onto joint.
5. Inner constant velocity joint
^ Outer diameter 100 or 108 mm depending on engine/transmission combination
^ Only replace complete
^ Pressing off see Fig. 3
^ Pressing on see Fig. 4
6. Drive shaft (tube shaft)
7. Hose clip
^ Always replace
8. Protective boot
^ Check for tears and chafing
9. Hose clip
^ Always replace
^ Tensioning see Fig. 1 and Fig. 5
10. Dished washer
^ Outer diameter (concave side) contacts thrust washer
11. Thrust washer
12. Circlip
^ Always replace
^ Insert in shaft groove
13. Outer constant velocity joint
^ Only Replace complete
^ Removing see Fig. 2
^ Installing: drive onto shaft on to stop with plastic hammer
14. Hex bolt
^ Changed to hex key head bolt
^ Replace each time after removing
Vehicle must be standing on ground when tightening
Tightening torque:
Bolt M14:
^ 115 Nm and turn 180° further
Bolt M16:
^ 190 Nm and turn 180° further
15. Multi-point socket head bolt
^ Tighten using diagonal sequence to 10 Nm
^ M8 x48; 40 Nm
^ M10 x 48; 77 Nm
16. Plate
17. Protective boot for inner constant velocity joint
^ Check for tears and chafing
^ Drive off with drift
^ Before installing on constant velocity joint, coat sealing surface with D-3
Joint protective boots made from rubber are tightened with pliers VAG 1275.
The instructions in Fig. 1 are only for hose clamps made from stainless steel!
Fig. 1 Tightening hose clamp on outer joint
- Install tensioning clamp VAG 1682 as shown in illustration. Thereby ensure that the jaws of the tension clamp seat in the corners (arrow B) of the hose clip.
- Tighten hose clamp by turning the spindle with a torque wrench (do not bend tensioning clamp).
Notes:
^ The hard material of the joint boot (compared to rubber) makes it necessary to use a stainless steel hose clamp, it is only possible to tighten the hose clamp with tensioning clamp VAG 1682.
^ Tightening torque: 20 Nm.
^ Use torque wrench with 5...50 Nm range (e.g. VAG 1331).
^ Make sure the spindle thread is not tight. If necessary lubricate with MOS 2 grease
^ If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct tightening torque settings.
Fig. 2 Pressing off outer constant velocity joint
- Clamp drive shaft in vice using vice clamps.
- Remove hose clip and slide back boot.
- Drive constant velocity joint off drive shaft using drift -A-.
Drive must be applied exactly on star of constant velocity joint.
Driving joint on
- Drive onto shaft with plastic hammer until securing ring engages.
Fig. 3 Pressing off inner constant velocity joint
Notes: First drive boot off with drill
Fig. 4 Pressing on inner constant velocity joint
- Press on joint up to stop.
- Insert circlip.
Note: Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive shaft.
Fig. 5 Ventilating joint boot
Only for joint protective boot of rubber
Often the boot is pushed in when installing on the joint body. This creates a vacuum inside the boot, which draws a fold in (arrow) while driving. Therefore after installing, lift the boot at small diameter end to equalize pressure.