I - Front Drive Axle With Constant Velocity (CV) Joint, Servicing

I - Front drive axle with Constant Velocity (CV) joint, servicing

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 dia. 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

Grease quantities and types
Grease filling of joints with high temperature grease Electronic Parts Catalog "ETKA"








1. Self-locking 12-point nut
^ Tightening
^ Remove any paint residue and/or corrosion in threads of outer joint before removing nut.

2. Right drive axle (tubular)
3. Socket head bolt
^ Tightening torques

4. Backing plate
5. Clamp
^ Replace
^ Tensioning

6. CV boot for inner Constant Velocity (CV) joint
^ Material: Hytrel (Polyelastomere)
^ without ventilation bore
^ Check for tears and scuffing
^ drive off constant velocity (CV) joint using a drift
^ before mounting on Constant Velocity (CV) joint, spread D 454 300 A2 on sealing surface

7. CV boot for inner Constant Velocity (CV) joint
^ Material: rubber
^ with ventilation bore
^ Check for tears and scuffing
^ drive off constant velocity (CV) joint using a drift
^ Installation position for left shaft
^ Installation position for right shaft
^ before mounting on Constant Velocity (CV) joint, spread D 454 300 A2 on sealing surface

8. Dished washer
^ Installed position

9. Inner Constant Velocity (CV) joint
^ Replace only as complete unit
^ Pressing off
^ Pressing on
^ Greasing
^ Checking Inner Constant Velocity (CV) joint, removing, checking and installing

10. Gasket
^ Bonding surface on CV joint must be free of grease and oil!
^ Replace
^ Pull off protective foil and bond into joint.

11. Circlip
^ Remove and install using VW 161 A

12. Left drive axle (full shaft)
^ Replace
^ Tensioning

13. Clamp
14. CV boot
^ Check for tears and scuffing
^ Material: Hytrel (Polyelastomere)

15. Vibration damper
16. Clamp
^ Replace
^ Tension using CV joint boot clamp tool V.A.G 1682

17. Dished washer
^ Installed position

18. Hex bolt
^ M10 X 28
^ Tightening torques

19. Protective cap
20. Thrust washer
^ Installed position

21. Circlip
^ Replace
^ insert in groove on shaft

22. Outer CV joint
^ Replace only as complete unit
^ Removing
^ Installing: Install on shaft using plastic hammer until impact
^ Greasing
^ Checking Outer Constant Velocity (CV) joint, removing, checking and installing





Removing outer constant velocity joint
- Drive off drive axle by hitting forcefully using a light metal hammer.





Pressing off inner constant velocity joint

Note: First, use a drift to drive off boot.





Installation position of spring washer at inner joint
1 - Dished washer





Installation position of spring washer and of thrust washer at outer joint
1 - Dished washer
2 - Thrust washer





Pressing on inner constant velocity joint
- Press on joint until it stops.
- Install lock ring.

Note: Chamfer on inner diameter of ball hub (splines) must face contact shoulder of drive axle.





Installation position of CV joint boot on left drive axle
Dimension "a" = 17 mm
Mark dimension "a" e.g. using paint or adhesive tape before installing CV joint boot on drive axle. Do not damage paint by using sharp objects under any circumstances.





Installation position of CV joint boot on right drive axle
Vent chamber - A - must sit on the pipe.
B - Ventilation opening





Tension the clamp on outer joint
- Use CV joint boot clamp tool V.A.G 1682 as shown in illustration. Be sure that edges of clamping pliers are seated in corners - arrows B - of hose clamp.
- Tighten hose clamp by turning spindle - A - using a torque wrench (do not tilt clamping pliers).

Note:
- A stainless steel clamp must be used due to the hardness of the CV boot material (compared to rubber). This clamp can only be tensioned using the CV joint boot clamp tool V.A.G 1682.
- Tightening torque: 25 Nm.
- Use torque wrench - C - with adjustment range 5...50 Nm (e.g. V.A.G 1331).
- Be sure thread of spindle - A - of clamp tool moves freely. Grease with grease MoS2 if necessary.
- If it does not move freely, e.g. due to dirt in thread, the required hose clamp tension will not be achieved at the specified torque.





Tightening clamp on inner joint/small diameter