Inner CV Joint, 100 mm Diameter or 108 mm Diameter
Inner CV Joint, 100 mm Diameter or 108 mm Diameter
Special tools, testers and auxiliary items required
• Thrust plate (VW 401)
• Thrust plate (VW 402)
• Punch (VW 409)
• Punch (VW 412)
• Support sleeve (VW 522)
• Clamp (40 - 204 A)
• Assembly tool (T10065) can also be used instead of clamp (40-204 A).
• Torque wrench (V.A.G 1331)
• CV joint boot clamp tool (V.A.G 1682)
• Circlip pliers (commercially-available)
Removing a 100 mm Diameter or 108 mm Diameter Inner CV Joint
- Secure the drive axle with protective covers in a vise clamp.
- Drive cover down with copper or brass drift.
- Drive cover down with copper or brass drift.
- Only open and remove the "small" protective boot clamp.
- Remove circlip.
- Remove the inner CV joint from the drive axle using the special tools illustrated.
- Remove the CV joint boot from the drive axle.
Removing a 100 mm Diameter or 108 mm Diameter Inner CV Joint
- Slide the protective joint boot with the "small" clamp onto the drive axle.
- Before installing joint piece, splines - A - must be lightly coated with grease used in joint.
- Press on joint until stop.
Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.
Use special tool shown in illustration.
You can also use the (T10065) instead of the (40-204 A).
(40-204 A) or (T10065) and clamping surfaces on drive shaft must be free of grease.
Circlip must be replaced.
- Install circlip.
- Check circlip for correct seating.
- Insert 50 grams of joint grease in the boot side of the joint before installing the protective boot.
- Lubricate the contact surface on the cover.
- Apply sealant "hatched surface" to clean surface on inner side of protective joint boot cover. Sealant bead: Uninterrupted, apply dia. 2 to 3 mm in area of inner holes - arrow -.
- Use sealant. Allocation, refer to the Electronic Parts Catalog (ETKA).
Protective boot and cap contact surfaces must be free of grease!
- Align new cover with screws - arrows - to screw holes.
It must be aligned exactly because it cannot be aligned after driving on.
- Drive cover on with a plastic hammer.
- Clear away leaking sealing immediately.
100 mm Diameter Inner CV Joint
- Apply 40 grams of joint grease to CV joint through ball paths.
108 mm Diameter Inner CV Joint
- Apply 70 grams of joint grease to CV joint through ball paths.
Procedure for both CV joints
- Lubricate the contact surface on the cover.
- Apply sealant "hatched area" to the clean surface in the inside of the cover. Sealant bead: Uninterrupted, apply diameter 2 to 3 mm in area of inner holes - arrow -.
- Use sealant Electronic Parts Catalog (ETKA).
- 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.
- Clear away leaking sealing immediately.
- Position CV boot in outer groove - arrow 2 -.
Inner groove - arrow 1 - remains visible "identification groove" (for correct installation of CV boot).
Install the clamp on inner joint and clamp it.
- Use (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 connecting tube.
- Tighten the clamp by turning the spindle using a torque wrench - C - (do not tilt the pliers).
• 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: 20 Nm.
• Use torque wrench with 5 to 50 Nm range (e.g. (V.A.G 1331) ).
• make sure the spindle threads on the pliers - A - move freely. Grease with MoS2 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.