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)

• Sleeve (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 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

Installed Location of Spring Washer and Thrust Washer on Outer Joint






1 - Dished washer

- Install the new circlips.

- Slide new CV boot onto drive axle if necessary.

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

Removing the Inner CV Joint






- Press off CV from joint using drift.

- Remove securing ring.

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

Assembling

Dished Washer Installation Position, Inner and Outer 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.

- Press on joint until stop.

- Install lock ring.

Tightening Hose Clamp on Outer Joint






- 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.

- 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).

• Torque 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