Rear Drive Axle With 100 mm Dia. Inner Constant Velocity Joint
Drive axle (with 100 mm dia. inner constant velocity joint), servicing
Special tools, testers and auxiliary items required
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Thrust disc VW 412
^ Tensioner 40-204.
^ Sleeve press tool VW 522
^ Punch VW 411
^ Hose clamp pliers V.A.G 1275
Grease quantity and type
Constant velocity joints are filled with grease G 000 603:
Regrease joint when replacing boot.
1 - Cover
^ Drive off carefully with drift
^ Always replace
^ Before installing on constant velocity joint, coat sealing surface with D 454 300 A2
^ Align cover with bolt holes.
2 - Circlip
^ Use commercially available circlip pliers when removing and installing
^ Always replace
3 - Inner constant velocity joint
^ Outside diameter: 100 mm
^ Replace only as a complete assembly
^ Pressing off
^ Pressing on
^ Greasing
^ Bonding surfaces must be free of oil and grease
4 - Bracket plate
5 - Socket-head bolt
^ Tightening torques:
^ M8 bolt: 40 Nm
^ M10 bolt: 65 Nm
6 - Boot for inner constant velocity joint cap
^ With vent hole
^ Drive cap off carefully with drift.
^ Always replace
^ Check inner constant velocity joint if boot is damaged
^ Before installing on constant velocity joint, coat sealing surface with D 454 300 A2
^ Align cover with bolt holes.
^ Sealing surfaces of drive axle boot must be free from grease when assembling
7 - Drive axle
8 - Boot for outer constant velocity joint
^ Without vent hole
^ Check for tears and chafing, replace if necessary
^ If damaged, check outer constant velocity joint
^ Sealing surfaces of boot to drive axle/joint must be free of grease during assembly
9 - Clamp
^ Always replace
^ Tightening
10 - Circlip
^ Always replace
^ Insert in shaft groove
11 - Outer constant velocity joint
^ Outside diameter: 88 mm
^ Replace only as a complete assembly
^ Driving off
^ Installing: drive onto shaft with plastic hammer until compressed circlip seats
^ When installing, circlip must lie in chamfer on joint; guide with pliers if necessary.
^ Greasing
12 - Collared bolt
^ Always replace
Pressing off outer constant velocity joint
- Clamp drive axle in vise using jaw protectors.
- Loosen hose clamp and push back boot.
- Drive constant velocity joint off drive axle using a drift - A -.
The drift must be positioned exactly on the star of the constant velocity joint.
Installing joint
- Knock constant velocity joint onto shaft with plastic hammer until circlip engages.
Tightening hose clip
Driving off cover from inner joint
Pressing off inner constant velocity joint
- Release circlip.
- Drive off boot with drift.
Note:
^ Support ball hub with thrust plate VW 402.
Pressing on inner constant velocity joint
- Press on joint as far as stop.
Use Sleeve-press tool VW 522.
- Engage circlip.
Note:
^ Chamfer on internal diameter of ball hub (splines) must face drive axle.
Coating sealing surface of cover and cap with D 454 300 A2
- 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.
- Remove excess sealant immediately as it is pressed out.