Drive Axle With Constant Velocity Joint, Servicing

Drive axle 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
^ Press piece 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

Grease quantity and type
^ Constant velocity joints are packed with high temperature grease.
^ Regrease joint, if necessary, when replacing the protective boot.





1. Outer constant velocity joint
^ Replace only as a unit
^ Removing
^ Installing: Using a plastic hammer, drive onto shaft as far as stop

2. Hex bolt
^ Changed from hex socket head bolt

Tightening torques:

Bolt M 14:
^ 115 Nm plus an additional 180° 1/2

Bolt M 16:
^ 190 Nm plus an additional 180° 1/2

When tightening, the vehicle must be on the ground.
^ Replace each time

3. Protective boot
^ Check for tears and chafing

4. Clamp
^ Always replace

5. Multi-point socket head bolt
^ M8 x 48, 40 Nm

6. Backing plate
7. 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

8. Circlip
^ Always replace
^ Remove and install with VW 161 A

9. Inner constant velocity joint
^ Replace only as a unit
^ Pressing off
^ Pressing on

10. Gasket
^ Replacing. Pull off protective foil and stick into joint.

11. Circlip
12. Axle shaft
13. Circlip
^ Not installed to all drive axles
^ Always replace
^ Remove and install with VW 161 A

14. Dished washer
^ Outer diameter (concave side) contacts thrust washer

15. Thrust washer
16. Circlip
^ Always replace
^ Insert in shaft groove





Pressing off outer constant velocity joint
^ Secure axle shaft with protective covers in vise clamp.
^ Remove clamp and slide boot back.
^ Drive constant velocity joint off axle 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.





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 bag hub (splines) must face the contact shoulder on the drive shaft.