Drive Axle, CV Joint VL100

Drive Axle, CV Joint VL100

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 408 A)

• Punch (VW 411)

• Tube 37 mm Dia. (VW 416 B)

• Thrust Pad (VW 447 H)

• Circlip Pliers (VW 161 A)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (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 Constant Velocity (CV) Joint

- Secure the drive axle with protective covers, in a vise.

- Fold back the outer CV joint boot.

- Align the puller (T10382) so that the flat side of the plate (T10382/1) faces the spindles (T10382/2).

- Attach the puller (T10382) to the slide hammer (VW 771/1/1).

- Remove the outer CV joint from the axle shaft using the puller (T10382) and slide hammer (VW 771/1/1).






1. Plate (T10382/1)

2. Spindles (T10382/2)


Installing the Outer CV Joint

Installed position: Concave washer and thrust washer on the outer CV joint





1 - Concave washer

2 - Thrust ring

- Install the new circlip.

- Slide new the CV joint boot onto the axle shaft, as necessary.

- Use a plastic hammer to install the boot on the shaft until the circlip locks secure.

Removing the Inner CV Joint





Assembling

- Slide the small clamp for the CV joint boot onto the axle shaft.

- Slide the CV joint boot onto the axle shaft.

Installed Position: Plate Spring on Inner CV Joint





1 - Plate Spring

Pressing on the Inner CV Joint





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

Tightening Hose Clamp on the Outer CV Joint Boot





- Attach the CV joint boot clamp tool (V.A.G 1682) as shown in the illustration. When doing this, make sure that the edges of the clamp tool are seated in the corners - arrows B - of the clamp.

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

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

• Tightening specification: 25 Nm

• Use a torque wrench - C - with an adjustment range of 5-50 Nm (for example, torque wrench (5-50 Nm) (V.A.G 1331) ).

• Be sure the threads of the spindle - A - on the clamp tool move freely. Grease them with MOS 2 grease if necessary.

• If they do not move freely, for example, due to dirt in the threads, the required clamping tension will not be achieved at the specified torque.

Tensioning the Small Diameter Clamp