Drive Axle With Constant Velocity (CV) Joint, Servicing

Drive axle with Constant Velocity (CV) joint, servicing
Grease quantities and types

Note: Grease CV joint with G 000 603 grease:








1. Outer CV Joint
^ Replace only as complete unit
^ Removing refer to Fig. 1
^ Installing: use plastic hammer to pound onto shaft until it stops and snap ring snaps into ring groove of Constant Velocity (CV) joint.
^ Note different version of thrust washer Item 15.
^ See Parts Supplier
2. Hex bolt
^ Always replace after disassembly
^ Tightening torques:
Bolt M14:
^ 115 Nm plus additional 180° (1/2 -turn)
Bolt M16:
^ 190 Nm plus additional 180 (1/2 -turn)
3. CV boot
^ Check for tears and scuffing
4. Clamp
^ Always replace
5. Socket-head bolt
^ M8 x 48: 40 Nm
^ M10 x 48: 70 Nm
6. Backing plate
7. CV boot for Inner Constant Velocity (CV) joint
^ Check for tears and scuffing
^ Drive off using drift
^ Before mounting on Constant Velocity (CV) joint spread D 454 300 A2 on sealing surface
8. Snap ring
^ Only installed in vehicles with full-length tubular shafts (A6 4.2)
^ Always replace
^ Remove and install using VW 161 a
9. Inner Constant Velocity (CV) joint
^ Replace only as complete unit
^ Pressing off refer to Fig. 2
^ Pressing on refer to Fig. 3
10. Gasket Replace, pull off protective foil and bond in joint.
11. Snap ring
^ Always replace
^ Remove and install using VW 161 a
12. Drive axle
^ Note different versions
^ See Parts Supplier
13. Snap ring
^ Only installed in vehicles with full-length tubular shafts (A6 4.2)
^ Always replace
^ Remove and install using VW 161 a
14. Dished washer
^ Large diameter (concave side) rests against thrust washer
15. Thrust washer
^ Note different versions
^ See Parts Supplier
16. Drive axle
^ Note different versions
^ See Parts Supplier
17. Snap ring
^ Always replace
^ Insert in groove on shaft





Special tools and equipment
^ VW401 thrust plate
^ VW402 thrust plate
^ 3207 pressing screw
^ VW 408 A punch
^ VW 522 sleeve press tool
^ 40-204 A press block





Special tools and equipment
^ 3340 pliers





Fig. 1 Pressing off outside Constant Velocity (CV) joint
^ Clamp drive axle in vise with protective pads.
^ Remove clamp and push back boot
^ Screw special tool with M 14 thread design into joint bolt until Constant Velocity (CV) joint is pressed off drive axle.





Fig. 2 Pressing off Inner constant velocity joint

Note:
^ First, use a drift to drive off boot.
^ Support ball hub.





Fig. 3 Pressing on Inner constant velocity joint
^ Press on joint until it stops.
^ Install lock ring.

Note: Chamfer on inner diameter of ball hub (splines) must face contact shoulder of drive axle.

Mounting CV boot





^ Mount clamp