Drive Axle Shaft With Constant Velocity (CV) Joint, Servicing
IV - Drive axle shaft with constant velocity (CV) joint, Servicing
Special tools and equipment
^ VW 161 A Circlip pliers
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 408 A Punch tool
^ VW 522 Sleeve-press tool
^ 40-204 A Press block
Special tools and equipment
^ VAG 1331 Torque wrench
^ VAG 1682 CV joint boot clamp tool
Grease quantity and type
CV joints are packed with grease G 000 603.
CAUTION:
Part numbers are listed here for reference only. Always check with your Parts department for the latest information.
If necessary, re-grease joint when replacing the CV joint protective boot.
1. Self-locking 12-point nut
^ Any paint residue and/or corrosion on thread of the outer joint must be removed before the nut is installed.
CAUTION: The vehicle must be standing on its wheels when loosening or tightening the 12-point nut. Otherwise there is risk of an accident.
2. Axle shaft, right (hollow shaft)
^ Right axle is longer than left axle
3. Multi-point socket head bolt
^ Always replace
^ M 8 x 48: 40 Nm (30 ft. lbs.)
^ M 10 x 48: 80 Nm (59 ft. lbs.)
4. Plate
5. Clamp
^ Always replace
^ Tightening, Refer to Fig 9
6. CV joint boot for inner CV joint
^ Material: Hytrel (Polyelastomer)
^ No vent hole
^ Check for tears and chafing
^ Drive off CV joint using a drift
^ Apply D 454 300 A2 on sealing surface before installing CV joint boot
7. CV joint boot for inner constant velocity joint
^ Material: Rubber
^ With vent hole
^ Check for tears and chafing
^ Drive off CV joint using a drift
^ Installation position for left drive axle, Refer to Fig. 6
^ Installation position for right drive axle, Refer to Fig. 7
^ Apply D 454 300 A2 on sealing surface before installing CV joint boot
8. Spring washer
^ Installation position
9. Inner CV joint
^ Only replace complete
^ Pressing off, Refer to Fig. 2
^ Pressing on, Refer to Fig. 5
10. Gasket
^ Always replace
^ Remove protective foil and stick gasket onto CV joint.
^ Adhesive surface on CV joint must be free of oil and grease!
11. Circlip
^ Use VW 161 A to remove and install
12. Axle shaft, left (solid shaft)
^ Right axle is longer than left axle
13. Clamp
^ Always replace
^ Tightening, Refer to Fig. 9
14. Protective CV joint boot
^ Check for tears and chafing
^ Material: Hytrel (Polyelastomer)
15. Vibration damper
^ Applies only for some vehicles versions
16. Clamp
^ Always replace
^ Tightening using pliers VAG 1682, Refer to Fig. 8
17. Spring washer
^ Installation position, Refer to Fig 4
18. Hex head bolt,
^ 35 Nm (26 ft. lbs.)
19. Heat shield
20. Thrust washer
^ Installation position
21. Circlip
^ Always replace
^ Install in shaft groove
22. Outer CV joint
^ Only replace complete
^ Removing, Refer to Fig. 1
^ Installing: drive onto shaft up to stop using plastic hammer
Fig. 1 Removing outer CV joint
- Drive joint off axle shaft with a firm blow from an aluminum hammer.
Fig. 2 Pressing off inner CV joint
Notes:
^ First use drift to drive off CV joint boot.
^ Support ball hub while pressing off.
Fig. 3 Installation position of spring washer on inner CV joint
1. Spring washer
Fig. 4 Installation position of spring washer and thrust washer on outer CV joint
1. Spring washer
2. Thrust washer
Fig. 5 Pressing on inner constant velocity joint
- Press on joint up to stop.
- Install circlip.
^ Chamfer on inner diameter of ball hub (splines)must face the contact shoulder on axle shaft.
Fig. 6 Installation position of CV joint boot on left axle shaft
Dimension -a-: 17 mm (0.669 inch)
Note:
Before assembling the CV joint boot on axle shaft mark position, dimension -a-, using paint or adhesive tape. Do not damage the paint (scratch or score paint surface) by using a sharp tool.
Fig. 7 Installation position of CV joint boot on right axle shaft
Vent chamber-A- must seat on tube.
B - Vent hole
Fig. 8 Tightening clamp outer CV joint hose
- Install VAG1682 CV joint boot clamp tool as shown in illustration. Make sure that jaws of pliers seat in corners (arrows -B-) of clamp.
- Tighten hose clamp by turning the spindle -A- with a torque wrench (do not bend pliers when doing this).
Tightening torque: 20 Nm (15 ft. lbs.).
Notes:
^ The CV joint boot material is hard (compared to rubber) and requires stainless steel clamps. Therefore it is only possible to tighten the clamp using VA G 1682 C V joint boot clamp tool.
Fig. 9 Tightening clamp (smaller diameter) on inner CV joint hose
Notes:
^ Use torque wrench -C- with a range of 5-50 Nm (approx. 5 40 ft. lbs.) (e.g. VAG 1331).
^ Make sure spindle -A- turns freely. If necessary lubricate the spindle threads with MOS 2 grease
^ If the spindle does not turn freely (e.g. spindle is dirty), the clamping force on the clamp will not be achieved even though the correct tightening torque is indicated.