108 mm Inner CV Joint
108 mm Inner CV Joint
Filling the Joints with Grease
• Grease joint again when replacing protective joint boot.
1 - Bolt
• Always replace if removed.
• There are different versions. Allocation, refer to the Electronic Parts Catalog (ETKA).
• Hex bolt: 200 Nm +180° turn. Loosening and tightening, refer to => [ Drive Axle Hex Bolt Connection, Loosening and Tightening ] Description and Operation.
• Twelve-point bolt with ribs: 70 Nm +90° turn. Loosening and tightening, refer to => [ Drive Axle Twelve-Point Bolt with Ribs, Loosening and Tightening ] Drive Axle Twelve-Point Bolt With Ribs, Loosening and Tightening.
• Twelve-point bolt without ribs: 200 Nm +180° turn. Loosening and tightening, refer to => [ Drive Axle Twelve-Point Bolt without Ribs, Loosening and Tightening ] Drive Axle Twelve-Point Bolt Without Ribs, Loosening and Tightening.
• Before installing, clean the threads in the CV joint with a tap.
• The vehicle must be on the ground when tightening.
2 - Outer CV Joint
• Replace only as complete unit.
• Checking, refer to => [ Outer CV Joint, Checking ] Outer CV Joint, Checking.
• Removing.
• Grease.
• Installing.
• When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
3 - Securing Ring
• Always replace if removed.
• Insert in shaft groove.
4 - Spacer Ring (Plastic)
• Installed position.
5 - Dished Washer
• Installed position.
6 - Clamp
• Always replace if removed.
• Tensioning or.
7 - CV Boot for Outer CV Joint
• Without ventilation bore.
• Check for tears and scuffing.
8 - Clamp
• Always replace if removed.
• Tensioning or.
9 - Profile Shaft
10 - Clamp
• Always replace if removed.
• Tensioning.
11 - Protective Boot for Inner CV Joint
• Check for tears and scuffing.
12 - Socket Head Bolt
• Always replace if removed.
• Pre-tightening specification: 10 Nm and diagonally.
• Tightening specification M8: 40 Nm and diagonally.
• Tightening specification M10: 70 Nm and diagonally.
13 - Backing Plate
14 - Clamp
• Always replace if removed.
• Tensioning.
15 - Inner CV Joint
• Replace only as complete unit.
• Checking, refer to => [ Inner CV Joint, Checking ] Inner CV Joint, Checking.
• When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
16 - Securing Ring
• Always replace if removed.
• Removing and installing using (VW 161 A).
17 - Cover
• Always replace if removed.
• Drive off CV joint using drift.
• Apply sealant D 454 300 A2 between joint and cover.
Removing the Outer CV Joint
- Remove the CV joint from the drive axle by hitting it with a light alloy hammer.
Location of Spacer Ring and Spring Washer on Outer Joint
1 Dished washer
2 Spacer ring (plastic)
Outer CV Joint with Bolt, Assembling
- Before installing joint piece, splines - A - must be lightly coated with grease used in joint.
- Install old drive shaft bolt in joint as shown in the illustration.
- Drive joint onto shaft with plastic hammer until circlip engages.
Inner CV Joint, Removing
Removing the Cover
- Drive cover down with copper or brass drift.
Circlip, Removing and Installing
- Drive out CV joint boot with a drift.
- Support ball hub when pressing off.
Pressing on Inner CV Joint
- Before installing joint piece, splines - A - must be lightly coated with grease used in joint.
- Press on joint until stop.
- Install circlip.
• Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.
Coat Cover Sealing Surface with D 454 300 A2 and Install
- Apply sealant -hatched area- to clean cover surface.
• Sealant bead: Uninterrupted, apply 2 to 0.3 mm diameter in area of inner holes - arrow -.
- Align new cover with bolts - arrows - to bolt holes.
• It must be aligned exactly because it cannot be aligned after driving on.
- Drive cover on with a plastic hammer.
- Wipe away any sealant leaking out.
Rubber Protective Joint Boot, Ventilating
The CV boot is frequently pressed in when placed on the CV joint body. This creates a vacuum in the CV boot, which pulls a fold inward when the car is driven - arrow -.
Therefore, note the following:
- Before clamping the clamping sleeves, balance pressure by raising protective joint boot.
Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning
- Position pliers (V.A.G 1682) as shown in illustration. When doing this, make sure that edges of clamping pliers are seated in corners - arrows B - of clamp.
- Tighten the hose clamp by turning spindle - A - using a torque wrench (do not tilt clamping pliers).
• Tightening specifications: 20 Nm
• Be sure thread of spindle in clamping pliers moves freely. Grease with MOS 2 grease, if necessary.
• If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.
Clamps for Rubber Protective Joint Boots, Tensioning
