Axle Shaft With Constant Velocity Joint, Servicing
Axle shaft with constant velocity joint, servicing
Special tools, testers and auxiliary items required:
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Punch VW 408 A
^ Punch VW 411
^ Thrust pad VW 447 H
^ Thrust tube VW 454
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
Special tools, testers and auxiliary items required
Pressure spindle 3207:
Grease quantity and type
As of 08.2004, a different grease has been introduced for the triple roller joint. This grease is not compatible with that which was previously used. Therefore, the triple roller joint must be cleaned of all grease when servicing.
^ Constant velocity joints are packed with high temperature grease.
^ Regrease joint, if necessary, when replacing protective boot.
1. Internal hex head bolt, 25 Nm
2. Heat shield
3. Circlip
^ Always replace
4. Gasket
^ Replacing. Pull off protective foil and stick into joint.
5. Inner constant velocity joint
^ Outer diameter 100 or 108 mm depending on engine/transmission combination
^ Replace only as a unit
^ Pressing off
^ Pressing on
6. Axle shaft (tube shaft)
7. Clamp
^ Always replace
8. Protective boot
^ Check for tears and chafing
9. Clamp
^ Always replace
10. Dish washer
^ Outer diameter (concave side) contacts thrust washer
11. Thrust washer
12. Circlip
^ Always replace
^ Insert in shaft groove
13. Outer constant velocity joint
^ Replace only as a unit
^ Installing: Using a plastic hammer, drive onto the shaft as far as the stop
14. Hex bolt
^ Was changed from hex socket head bolt
^ Replace each time after removing
When tightening, the vehicle must be on the ground.
Tightening torques
Bolt M 14:
^ 115 Nm plus an additional 180° 1/2 turn
Bolt M 16:
^ 190 Nm plus an additional 180° 1/2 turn
15. Multi-point socket head bolt
^ Tighten diagonally to 10 Nm
^ M 8 x 48, 40 Nm
^ M 10 x 48, 77 Nm
16. Backing 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 454 300 A2
Joint protective boots made from rubber are tightened with pliers V.A.G 1275.
The instructions in Fig. 1 are only for hose clamps made from stainless steel!
Tightening hose clamp on outer joint
^ Install tensioning clamp V.A.G 1682 as shown in illustration. Make sure that the jaws of the tension clamp seat in the corners - arrows B - of the hose clip.
^ Tighten hose clamp by turning spindle with a torque wrench (do not bend tensioning clamp).
Note:
^ 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 V.A.G 1682.
^ Tightening torque: 20 Nm
^ Use torque wrench with 5 to 50 Nm range (e.g. V.A.G 1331).
^ Make sure the spindle thread is not tight. If necessary lubricate with grease MoS2.
^ 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.
Pressing off outer constant velocity joint
^ Secure axle shaft with protective covers in vise clamp.
^ Remove clamp and slide boot back.
^ Tighten pressure spindle 3207 with the M16 thread pattern into joint pin, until constant velocity joint separates from the axle shaft.
Driving on outer constant velocity joint
^ Drive onto shaft with plastic hammer until securing ring engages.
Pressing off inner constant velocity joint
Note:
^ First drive boot off with drift
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 axle shaft.
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.