Rear Suspension

Drive axle with constant velocity (CV) joint, servicing





Special tools, testers and auxiliary items required
^ Circlip pliers VW 161A
^ Punch VW 408A
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Sleeve-press tool VW 522
^ Press block 40-204A
^ CV joint boot clamp tool V.A.G 1682
^ Torque wrench 5 - 50 Nm V.A.G 1331

Grease quantities and types
CV joints are packed with G 000 603 grease:








1 - Self-locking 12-point nut
^ Tightening
^ Remove any paint residue or corrosion on thread of outer joint before installing nut.

2 - Outer CV joint
^ Replace as complete unit
^ Removing
^ Installing: drive onto shaft as far as stop using plastic hammer

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

4 - Thrust washer
^ Installation position

5 - Convex washer
^ Installation position

6 - Hose clamp
^ Always replace
^ Tightening

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

8 - Hose clamp
^ Always replace
^ Tightening

9 - Axle shaft (solid shaft)

10 - Socket head bolt, 40 Nm

11 - Lock plate

12 - Hose clamp
^ Always replace
^ Tightening

13 - Boot for inner CV joint
^ Check for tears and scuffing
^ Drive off using drift

14 - Convex washer
^ Installation position

15 - Inner constant velocity joint
^ Replace as complete unit
^ Pressing off
^ Pressing on
^ Greasing

16 - Gasket
^ Replace: Pull off protective foil and stick onto joint.

17 - Snap ring





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





Installation position of convex washer and thrust washer at outer joint
1 - Convex washer
2 - Thrust washer





Installation position of convex washer at inner joint
1 - Convex washer





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 lock ring.

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





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).





Tightening small hose clamp
- Tighten hose clamp by turning spindle with torque wrench (keep pliers straight).

Note:
^ Tightening torque: 20 Nm.
^ Use torque wrench - C - (adjustment range 5 to 50 Nm), e.g. V.A.G 1331.
^ Make sure thread of spindle - A - 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 when applying the specified tightening torque.