89 mm or 94 mm Outer CV Joint

89 mm or 94 mm Outer CV Joint

Special tools, testers and auxiliary items required

• CV joint boot clamp tool (3340)

• CV joint boot clamp tool (V.A.G 1682)

• Torque wrench (V.A.G 1331)

• Circlip pliers (commercially-available)

• Copper or brass drift

• Sealant. Allocation, refer to the Electronic Parts Catalog (ETKA).

Removing






- Secure the drive axle with protective covers in a vise clamp.

- Open the clamps.

- Slide back protective boot.

- Drive CV joint from drive axle using a drift - A -.

Drift - A - must be installed exactly on the triple roller star of the CV joint.

- Remove the dished washer.

- Remove joint and protective joint boot.






- Remove the circlip - 1 -.

Installing






- Push the joint protective boot and a new clamp onto the drive axle.

• Joints and protective joint boots must be free of grease.

- Position the joint protective boot between the - arrows - into the groove - 2 -.

1 Circlip (snap ring), always replace.
2 Positioning groove, push the joint protective boot into the groove until it engages.

- Push the dished washer onto the drive axle, where applicable.






Outer Constant Velocity Joint, 89 mm

- Place 70 grams of drive axle grease evenly into the joint.

Outer Constant Velocity Joint, 94 mm

- Place 80 grams of drive axle grease evenly into the joint.

Continuation for Both Constant Velocity Joints






- Before installing joint piece, splines - A - must be lightly coated with grease used in joint.

- Insert sealing ring in groove on shaft.

- Slide on CV joint up to sealing ring.






- Align sealing ring at center with opening upward - see arrows -.

- Install the old drive axle bolt in the joint as shown in the illustration.






- Drive joint onto drive axle with plastic hammer until circlip engages.

- Install the joint protective boot onto the metal cap.

- Bleed protective joint boot.

- Tension clamps on outer joint.

Tightening Hose Clamp on Outer Joint

Applies to the small and large clamps.

Depending on the version of the clamp, use the following tools:

Mount and tension stainless steel clamps using (V.A.G 1682) as illustrated.






- When doing this, make sure that edges of clamping pliers are seated in corners - arrows B - of clamp.

- Tighten the clamp by turning the spindle using a torque wrench (do not tilt the pliers).

• A stainless steel clamp must be used due to the hardness of the CV boot material (compared to rubber). This clamp can only be tensioned using the (V.A.G 1682).

• Tightening specifications: 20 Nm.

• Use torque wrench with 5 to 50 Nm range (e.g. (V.A.G 1331) ).

• make sure the spindle threads on the pliers - A - move freely. Grease with MoS2 grease if necessary.

• If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.

Mount and tension the clamp with the retaining tabs using (3340) as illustrated.






- Engage the clamp at the first catch by hand.

- Close the clamp using (3340).