Front Suspension

Drive axle with Constant Velocity (CV) joint, servicing





Grease quantity and type
Constant velocity joints are packed with grease G 000 603:





Regrease joint when replacing boot.

1 - Outer constant Velocity (CV) joint
^ Replace only as complete unit
^ Removing
^ Installing

2 - Hex bolt
^ Always replace if removed Tightening torque

3 - Self-locking 12-point nut

4 - Outer constant Velocity (CV) joint
^ Replace only as complete unit
^ Removing
^ Installing: drive onto shaft with plastic hammer until compressed circlip seats

5 - Circlip
^ Always replace
^ Insert in groove on shaft

6 - Spacer ring (plastic)
^ Installation position

7 - Convex washer
^ Installation position

8 - Hose clamp
^ Always replace
^ Tightening

9 - CV Boot
^ Check for tears and scuffing
^ Material: Hytrel (polyelastomer)

10 - Hose clamp
^ Always replace
^ Tightening

11 - Axle shaft

12 - Socket-head bolt
Initial tightening torque: 10 Nm
Tightening torque: 70 Nm

13 - Lock plate

14 - CV boot for inner constant velocity (CV) joint
^ Material: Rubber
^ With vent hole
^ Check for tears and scuffing
^ Drive off CV joint using a drift
^ Apply sealant D454300A2 between joint and cover.

15 - Inner constant velocity (CV) joint
^ Replace only as complete unit
^ Pressing off
^ Pressing on

16 - Circlip
^ Always replace
^ Remove and install with VW161 a

17 - Cover
^ Always replace
^ Drive off CV joint using a drift
^ Apply sealant D454300A2 between joint and cover.





Removing outer constant velocity joint
- Drive joint off axle shaft with a firm blow from an aluminum hammer.





Pressing off inner constant velocity joint

Note:
^ First drive off boot with drift.
^ Support ball hub.





Pressing on inner constant velocity joint
- Press on joint as far as stop.
- Install circlip.

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





Installing outer constant velocity (CV) joint with flange bolt
- Screw old bolt into CV joint as shown.
- Use plastic hammer to drive joint onto shaft until circlip engages.





Venting CV boot
The CV boot is often squashed when it is installed on the joint body. This creates a partial vacuum inside the boot which draws in a fold - arrow - while driving. For this reason, vent the boot to equalize the pressure after installation by briefly lifting the lip at the small-diameter end.





Tightening hose clamp on outer joint
- Apply pliers V.A.G 1682 as shown. Make sure that the jaws of the pliers seat in the ends of the hose clamp - arrows B -.
- Tighten hose clamp by turning spindle with torque wrench (keep pliers straight).

Note:
^ Due to the hard material of the CV joint boot (as opposed to rubber), a stainless steel hose clamp is required; this can only be tightened using pliers V.A.G 1682.
^ Tightening torque: 25 Nm.
^ Use torque wrench with 5 to 50 Nm range (e.g. V.A.G 1331).
^ Make sure thread of spindle on pliers moves freely. Lubricate with MoS2 grease if necessary.
^ If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clamp with the specified tightening torque.





Tightening hose clamp at small diameter of boot





Installation position of spacer ring and convex washer (wheel end)
1 - Convex washer
2 - Spacer ring (plastic)





Coat sealing surface of cover and cap with D454300A2.
- Apply sealant on clean surface of cover and cap (hatched area). Route continuous bead of sealant (2 to 3 mm diameter) around inside of holes - arrow -.
- Align cover and cap with bolt holes and drive or press onto joint.
- Wipe off surplus sealant.