Rear Suspension
Drive Axle with 82 mm Outer CV Joint
1 Outer CV Joint
• Replace only as complete unit
• Removing.
• Installing: Install all the way onto the shaft using a plastic hammer.
• Divide the grease evenly in the joint.
• Checking, refer to => [ Outer CV Joint, Checking ] Outer CV Joint, Checking.
2 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 ] Drive Axle Hex Bolt Connection, Loosening and Tightening.
• 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.
3 Drive Axle
• Allocation, refer to the Electronic Parts Catalog (ETKA).
4 Clamp
• Always replace if removed.
• Tensioning.
5 Protective Boot
• Check for tears and scuffing.
• Material: Hytrel (Polyelastomer).
6 Clamp
• Always replace if removed.
• Tensioning.
7 Dished Washer
• With inner splines.
• Installed position.
8 Securing Ring
• Always replace if removed.
• Insert in shaft groove.
9 CV Boot
• Material: Hytrel (Polyelastomer).
• Without ventilation bore.
• Check for tears and scuffing.
• Drive off CV joint using drift.
• Before mounting onto CV joint, coat sealing surface using (D 454 300 A2).
10 Clamp
• Always replace if removed.
• Tensioning.
11 Backing Plate
12 Socket Head Bolt
• First tighten diagonally to 10 Nm, then tighten diagonally again to the tightening specification.
• Tightening specification M8: 40 Nm and diagonally.
• Tightening specification M10: 70 Nm and diagonally.
• Always replace bolts after disassembly.
13 Securing Ring
• Always replace if removed.
• Remove and install using snap ring pliers (VW 161 A).
14 Gasket
• Always replace if removed.
• Bonding surface on CV joint must be free of grease and oil!
15 Inner CV Joint
• Replace only as complete unit.
• Divide the grease evenly in the joint.
• Pressing off.
• Pressing on.
• Checking, refer to => [ Inner CV Joint, Checking ] Inner CV Joint, Checking.
16 Dished Washer
• With inner splines.
Disassembling and Assembling
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)
• Locking Ring Pliers (VW 161 A)
• Torque Wrench 5-50 Nm (V.A.G 1331)
• Torque Wrench 40-200 Nm (V.A.G 1332)
• CV Joint Boot Clamp Tool (V.A.G 1682)
• Assembly Tool (T10065)
Disassembling
Outer CV Joint, Pressing Off
- Secure the drive axle with protective covers in a vise clamp.
- Fold back boot.
- Drive CV joint from drive axle using a drift - A -.
• Drift must be placed precisely on star of CV joint.
Driving Joint On
- Drive onto shaft with plastic hammer until securing ring engages.
Removing the Inner CV Joint
- Press off CV from joint using drift.
- Remove securing ring.
- Remove both clamps, and push joint boot toward outer joint.
Assembling
Dished Washer Installation Position, Inner and Outer Joint
1. Dished washer
- Press on joint until stop.
- Install lock ring.
Pressing On Inner CV Joint
• Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.
Tightening Hose Clamp on Outer Joint
- Attach (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.
- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).
• 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 (V.A.G 1682).
• Tightening specifications: 25 Nm.
• Use torque wrench - C - with adjustment range 5 to 50 Nm (for example (V.A.G 1331) ).
• Be sure thread of spindle - A - of clamp tool 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 tightening specification settings.
Tensioning Clamp on Small Diameter
