Drive Axle With Triple-Rotor Joint, Servicing

Drive Axle With Triple Rotor Joint, Servicing
Grease quantity and type

Note:
- Pack the outer constant velocity joints with these types of greases:
- 88 mm joint diameter: G 000603
- 98 mm joint diameter: G 000633








CAUTION: Part numbers are listed here for reference only. Always check with your Parts supplier for the latest information.

1. Drive axle with triple rotor joint
- Replacement part supplied with boot and filled with grease
2. Clamp
- Always replace
- Tightening refer to Fig. 1
3. Boot for inner triple rotor joint
- Check for splits and abrasions
- Only 32 mm diameter shafts have replaceable inner boots
- To replace, drive off outer constant velocity joint
- When slipping onto profiled shaft, apply small quantity of grease to bead on profiled shaft and use VAG1474/5 wedge (part of VAG1474) to carefully position boot refer to Fig. 4
4. Clamps
- Always replace
- Tightening refer to Fig. 1
5. Boot for outer constant velocity joint
- Check for splits and abrasions
- Before tightening clamp, briefly lift end of boot to equalize pressure (ventilate) refer to Fig. 3
- As of chassis no. 8DTA 279 794, new boots were introduced for 88 mm outer joint (wheel end) refer to Fig. 1
6. Clamp
- Always replace
- Tightening refer to Fig. 1
7. Spring washer
- Installation position refer to Fig. 5
8. Spacer washer (plastic)
- Installation position refer to Fig. 5
9. Circlip
- Always replace
- Install into circular groove on axle shaft before installing joint
- Not visible with joint installed
10. Outer constant velocity joint
- Outer diameter 88 or 98 mm, depending on engine/transmission combination
- Replace as complete part only
- Pressing off refer to Fig. 2 (with hollow shaft.
- Installing: use plastic hammer to drive onto axle shaft until circlip engages.
Clamps used on rubber joint boots are tightened using VAG1275 pliers
Instructions in Fig. 1 are only for stainless steel clamps





Fig. 1 Tightening clamp on outer CV joint
- Position VAG1682 pliers as shown in illustration. Make sure jaws of pliers seat in grooves of clamp (arrows -B)
- Using torque wrench, turn spindle -A- and tighten clamp.
- Do not cant pliers
- Tightening torque: 20 Nm (15 ft. lbs.)

Notes:
- Use a torque wrench with a range of 5-50 Nm (approx. 4 - 40 ft. lbs.) (e.g. VAG1331).
- Make sure spindle -A- turns freely. If necessary lubricate the spindle threads with MOS2 grease.
- If the spindle does not turn freely (e.g. spindle is dirty), the clamping force required on the clamp will not be achieved even though the correct tightening torque is indicated.





Fig. 2 Pressing off outer constant velocity joint
- Clamp drive axle in vise using protective jaw covers.
- Remove large clamp and slide back boot.
- Thread special tool into end of constant velocity joint until joint is pressed off of axle shaft.





Fig. 3 Ventilating joint boot
Only for rubber joint boot
The joint boot is often pressed in while being installed on the body of the joint. This creates a vacuum inside the boot which draws it inward with a fold (arrow) while driving. Therefore after installing, lift the boot at the small diameter end to equalize pressure.





Fig. 4 Positioning boot over bead of profiled shaft





Fig. 5 Installation positions of spacer washer and spring washer (outer CV joint end)
1. Spring washer
2. Spacer washer (plastic)