Rear Drive Axle With 108 mm Dia. Inner Constant Velocity Joint
Drive axle (with 108 mm dia. inner constant velocity joint), servicing
Special tools, testers and auxiliary items required
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Punch VW 409
^ Thrust disc VW 412
^ Sleeve press tool VW 522
^ Tensioner 40-204.
^ Assembly tool T10065/4
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
^ Apply D 454 300 A2 to sealing surface before installing to constant velocity joint
^ Align cover with bolt holes
2 - Circlip
^ Use commercially available circlip pliers when removing and installing
^ Always replace
3 - Inner constant velocity joint with cap for boot
^ Outside diameter: 108 mm
^ Replace only as a complete assembly
^ Pressing off
^ Pressing on
^ Greasing
^ Adhesive surfaces must be free of oil and grease
4 - Lock plate
5 - Socket-head bolt
^ Tightening torques:
^ M8 bolt: 40 Nm
^ M10 bolt: 65 Nm
6 - Clamp
^ Always replace
^ Tightening
7 - Boot for inner constant velocity joint
^ With vent hole
^ Check for tears and chafing, replace if necessary
^ If damaged, check inner constant velocity joint
^ Sealing surfaces of boot to drive axle/cap must be free of grease during assembly
8 - Drive axle
9 - Boot for outer constant velocity joint
^ Outside diameter: 88 mm
^ 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/cap must be free of grease during assembly
10 - Clamp
^ Always replace
^ Tightening
11 - Circlip
^ Always replace
^ Insert in shaft groove
12 - Outer constant velocity joint
^ Replace only as a complete assembly
^ Driving off
^ Installing: drive onto shaft with plastic hammer until compressed circlip seats
^ Circlip must fit in chamfer on joint when installing; guide with pliers if necessary.
^ Greasing
13 - Collared bolt
^ Always replace
Pressing off inner constant velocity joint
- Release circlip.
- Drive off boot with drift.
Note:
^ Cap - A - must not rest on thrust plate VW 401. For this reason, use shells T1006514 as spacers.
Pressing on inner constant velocity joint
- Press on joint as far as stop.
- Engage circlip.
Note:
^ Position ball hub with inside diameter chamfer (splines) on drive axle.