I - Front Drive Axle With Constant Velocity Joint, Servicing
I - Front 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
^ Sleeve 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 quantity and type
Filling drive axle with high temperature grease.
1 - Self-locking 12-point nut
^ Tightening
^ Any paint residue and/or corrosion on thread of the outer joint must be removed before the nut is installed.
^ Always replace
2 - Outer constant velocity joint
^ Replace as a unit
^ Removing
^ Installing: Using a plastic hammer, drive onto axle as far as the stop
^ Greasing
^ Checking go to Outer constant velocity joint, checking
3 - Circlip
^ Always replace
^ Insert in shaft groove
4 - Thrust washer
^ Installation location
5 - Spring washer
^ Installation location
6 - Clamp
^ Always replace
^ Tightening with pliers V.A.G 1682
7 - Protective boot
^ Check for tears and chafing
^ Material: Hytrel (Polyelastomer)
8 - Clamp
^ Always replace
^ Tightening
9 - Axle shaft
10 - Clamp
^ Always replace
^ Tightening
11 - Protective boot for inner constant velocity joint
^ Material: Hytrel (Polyelastomer)
^ No vent hole
^ Check for tears and chafing
^ Drive off constant velocity joint with a drift
^ Before installing on constant velocity joint, coat sealing surface with D 454 300 A2
12 - Protective boot for inner constant velocity joint
^ Material: Rubber
^ With vent hole
^ Check for tears and chafing
^ Drive off constant velocity joint with a drift
^ Installation position for left drive axle
^ Installation position for right drive axle
^ Before installing on constant velocity joint, coat sealing surface with D 454 300 A2
13 - Plate
14 - Multi-point socket head bolt
15 - Spring washer
^ Installation location
16 - Inner constant velocity joint
^ Replace only as a unit
^ Pressing off
^ Pressing on
^ Greasing
^ Checking go to Inner constant velocity joint, checking
17 - Gasket
^ Adhesive surface on constant velocity joint must be free of oil and grease!
^ Always replace
^ Pull off protective foil and stick gasket onto joint.
18 - Circlip
^ Remove and install with VW 161 a
19 - Hex bolt, 35 Nm
20 - Protective cap
Removing outer constant velocity joint
- Drive joint off axle shaft with a firm blow from a plastic hammer.
Pressing off inner constant velocity joint
Note:
^ First drive boot off with drift
Installing spring washer on inner joint
1 -Spring washer
Installing spring washer and thrust washer on outer joint
1 - Spring washer
2 - Thrust washer
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 axle shaft.
Installing joint protective boot on left axle shaft
Dimension - a - = 17 mm
Before installing boot mark position, measure - a - (for example paint or adhesive tape). Under no circumstances should paint surface be damaged with a sharp tool.
Installing boot for constant velocity joint (right drive axle)
The vent chamber - A - must seat on tube.
B - Vent hole
Tightening clamp on outer CV joint boot
- Install tightening clamp V.A.G 1682 as shown in illustration. Make sure that the jaws of the tension clamp seat in the comers -arrows B - of the hose clip.
- Tighten hose clamp by turning the spindle with a torque wrench (do not bend tensioning clamp).
Note:
^ Due to he 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 clamping device V.A.G. 1682.
^ Tightening torque: 25 Nm
^ Use torque wrench - C - with a range of 5 to 50 Nm (e.g. V.A.G. 133 1).
^ Make sure the spindle thread - A - is not tight If necessary lubricate with grease MOS 2.
^ If the thread is tight e.g. dirty, the required tensioning force for the clamp will not be achieved in spite of correct tightening torque settings.
Tightening clamp for CV joint boot (inner, small dia.)
