Drive Axle with Bolted CV Joint VL107

Drive Axle with Bolted CV Joint VL107

Special tools, testers and auxiliary items required

• Thrust plate (VW 401)

• Thrust plate (VW 402)

• Punch (VW 408 A)

• Support sleeve (VW 522)

• Clamp (40 - 204 A)

• CV joint boot clamp tool (V.A.G 1682)

• Torque wrench (V.A.G 1331)

• Slide hammer - complete set (VW 771)

• Puller (T10382)

Removing the Outer CV Joint

- Secure the drive axle with protective covers in a 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. (T10382/1)

2. (T10382/2)


Driving on Outer CV Joint

- Install the new circlips.

- Slide new CV boot onto drive axle if necessary.

- Drive it onto shaft with plastic hammer until securing ring engages.

Drive Off Cover for Inner Joint





- Remove securing ring.

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

- Drive out CV joint boot with a drift.

Removing the Inner CV Joint





Assembling

Pressing On Inner CV Joint





- Press on joint until stop.

- Install lock ring.

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






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

- Align new cover with bolts - arrows - to screw holes.






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

- Drive cover on with a plastic hammer.

- Wipe away any sealant leaking out.

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).

• The hard material of the joint boot (compared to rubber) makes it necessary to use a stainless steel hose clamp. It is only possible to tighten the hose clamp with (V.A.G 1682).

• Tightening specification: 25 Nm.

• Use torque wrench - C - with adjustment range 5 to 50 Nm (e.g. (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, e.g. due to dirt in thread, the required clamp tension will not be achieved at the specified torque.

Tensioning Clamp on Small Diameter