Drive Axle, with CV Joint VL107 Bolted to Intermediate Shaft

Drive Axle, with CV Joint VL107 Bolted to Intermediate Shaft

Special tools, testers and auxiliary items required

• Thrust plate (VW 401)

• Thrust plate (VW 402)

• Punch (VW 408A)

• Sleeve-press tool (VW 522)

• Press block (40-204A)

• CV joint boot clamp tool (VAG 1682)

• Torque wrench 5-50 Nm (VAG 1331)

Disassembling

Removing the Outer Constant Velocity (CV) Joint





- Secure the axle shaft in a vise with protective covers on the vise jaws.

- Fold back the CV joint boot.

- Drive the CV joint from axle shaft using a drift - A -. The force must be applied exactly to the triple roller star of the CV joint.

Driving Off Cover for Inner CV Joint





- Remove the securing ring.

- Remove both clamps and slide the CV joint boot toward the outer CV joint.

- Drive off the CV joint cover with a drift.

Removing the Inner CV Joint





Assembling

Installed Location of Spring Washer for Inner CV Joint





1 - Dished washer

Installed Location of Spring and Thrust Washers for Outer CV Joint





1 - Dished washer

2 - Thrust washer

Installing the Inner CV Joint





- Press on the inner CV joint until seated.

- Install the lock ring.

- Coat the cover sealing surface with (D 454 300 A2).





- Apply an unbroken sealant bead with a 2 to 3 mm diameter in area of the inner holes - arrow - to a clean cover surface.

- Align the new cover using 2 bolts - arrows - to the holes.





It must be aligned exactly because it cannot be aligned after driving on.

- Drive cover on using a plastic hammer.

- Wipe away any sealant leaking out.

Installing the Outer CV joint

- Drive the outer CV joint onto the axle shaft using a plastic hammer until the securing ring engages.

Tensioning Clamp for Outer CV Joint Boot





- Attach the (VAG 1682) as shown in illustration. Be sure that the edges of the (VAG 1682) are seated in the corners - arrows B - of the hose clamp.

- Tension clamp by turning the spindle with a torque wrench (do not tilt clamp tool).

• A stainless steel clamp must be used due to the hardness of the CV joint boot material (compared to rubber). This clamp can only be tensioned using (VAG 1682).

• Tightening specification: 25 Nm.

• Use a torque wrench - C - with an adjustment range of 5-50 Nm (e.g. (VAG 1331)).

• Be sure the threads of the spindle - A - on the (VAG 1682) move freely. Grease with MOS 2 grease if necessary.

• If they do not move freely, e.g. due to dirt in the threads, the required clamp tension will not be achieved at the tightening specification.

Tensioning Clamp for Inner CV Joint Boot