Drive Axle, with CV Joints VL90 and VL100

Drive Axle, with CV Joints VL90 and VL100

Special tools, testers and auxiliary items required

• Thrust plate (VW 401)

• Thrust plate (VW 402)

• Punch (VW 408A)

• Punch (VW 411)

• Tube 37 mm dia, (VW 416B)

• Thrust pad (VW 447H)

• Circlip pliers (VW 161A)

• Torque wrench 5-50 Nm (VAG 1331)

• Torque wrench 40-200 Nm (VAG 1332)

• CV joint boot clamp tool (VAG 1682)

• Assembly tool (T10065)

• Thrust tube (VW 454)

Disassembling

Removing the Outer Constant Velocity (CV) Joint





- Secure the axle shaft in a vise using 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.

- Remove the securing ring.

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

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





• The chamfer on the inner diameter of the ball hub (splines) must face the contact shoulder of axle shaft.

Installing the Outer CV Joint

- Slide the new CV boot on to drive axle if necessary.

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

- Install the securing ring.

Tensioning Clamp for Outer CV Joint Boot





- Attach the (VAG 1682) as shown in illustration. When doing this, make sure that edges of (VAG 1682) are seated in the corners - arrows B - of the clamp.

- Tension the 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