Rear Suspension
Drive Axle
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Punch (VW 411)
• Tube 31.5 mm Dia. (VW 416 B)
• Thrust Pad (VW 447 H)
• Circlip Pliers (VW 161 A)
• Torque Wrench (V.A.G 1331)
• Torque Wrench (V.A.G 1332)
• CV Joint Boot Clamp Tool (V.A.G 1682)
• Assembly Tool (T10065)
• Slide Hammer - Complete Set (VW 771)
• Puller (T10382)
Removing Outer Constant Velocity Joint
- Secure drive axle with protective covers in vise clamp.
- Fold back boot.
- Align the (T10382) so that the flat side of the plate (T10382/1) faces the spindles (T10382/2).
- Attach the (T10382) to the (VW 771).
- Remove the CV joint from the drive axle using the (T10382 ) and (VW 771).
1. Plate (T10382/1)
2. Spindles (T10382/2)
Driving on Outer CV Joint
Installed Location of Spring Washer and Thrust Washer on Outer Joint
1 - Dished washer
2 - Thrust washer
- Install the new circlips.
- Slide new CV boot onto drive axle if necessary.
- Drive it onto shaft with plastic hammer until securing ring engages.
Disassembling
Pressing off Inner Constant Velocity Joint
Assembling
Installed Location of Spring Washer on Inner Joint
1. Dished washer
Pressing on Inner CV Joint
• Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.
- Attach (V.A.G 1682) as shown in illustration. Be sure that edges of clamping pliers are seated in corners - arrows B - of hose clamp.
Tightening Hose Clamp on Outer Joint
- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).
• A stainless steel clamp must be used due to hardness of CV boot material (compared to rubber). This clamp can only be tensioned using (V.A.G 1682).
• Tightening specification: 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 it does not move freely, for example due to dirt in thread, the required clamp tension will not be achieved at the specified torque.
Tensioning Clamp on Small Diameter
Assembling
Installed Location of Spring Washer on Inner Joint
1. Dished washer
Installed Location of Spring Washer and Thrust Washer on Outer Joint
1. Dished washer
2. Thrust 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.
- Attach (V.A.G 1682) as shown in illustration. Be sure that edges of clamping pliers are seated in corners - arrows B - of hose clamp.
Tightening Hose Clamp on Outer Joint
- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).
• A stainless steel clamp must be used due to hardness of CV boot material (compared to rubber). This clamp can only be tensioned using (V.A.G 1682).
• Tightening specification: 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 it does not move freely, for example due to dirt in thread, the required clamp tension will not be achieved at the specified torque.
Tensioning Clamp on Small Diameter