Drive Axle With the Outer CV Joint 107 mm and the Inner CV Joint 112 mm
Drive Axle with the Outer CV Joint � 107 mm and the Inner CV Joint � 112 mm
Removing and installing, refer to => [ Drive Axle Assembly Overview, with Outer Constant Velocity Joint � 107 mm and Inner Constant Velocity Joint � 112 mm ] Drive Axle Assembly Overview, With Outer Constant Velocity Joint 107 mm and Inner Constant Velocity Joint 112 mm.
Special tools, testers and auxiliary items required
• Thrust plate (VW 401)
• Thrust plate (VW 402)
• Punch (VW 408 A)
• Support sleeve (VW 522)
• Shop press (V.A.G 1290A)
• CV joint boot clamp tool (V.A.G 1682)
• Torque wrench (V.A.G 1331)
• Circlip pliers (commercially-available)
• Copper or brass drift
Inner CV Joint, Removing and Installing
Removing
- Secure drive axle with protective covers in vise clamp.
- Remove small clamp from the joint protective sleeve.
- Uniformly drive off the inner joint cover with a brass or copper drift.
- Uniformly drive off the cap from the joint protective sleeve using a brass or copper mandrel.
- Remove the retaining ring.
- Press the inner CV joint off of the drive axle with the tools shown in the figure on the (V.A.G 1290A).
1. (VW 401) or (VW 402)
2. (VW 408 A)
- Pull the inner joint off of the drive axle.
Installing
- Slide the protective joint boot with the small clamp onto the drive axle.
- Before installing joint piece, splines - A - must be lightly coated with grease used in joint.
- Clamp the drive axle with protective covers in the vise as shown in the figure.
- Carefully position the joint on the profile shaft using the (VW 522) and install it all the way using a hammer.
1. Protective covers
2. Inner constant velocity joint
3. (VW 522)
- Install a new circlip.
- Check circlip for correct seating.
- Add half of the drive axle grease into the joint on the boot side before installing the joint protective boot.
- Lubricate the contact surface on the cover.
- Apply sealant - hatched surface - to clean surface on inner side of protective joint boot cap.
- 2 - 3 mm unbroken sealant bead dia.
- The inner sealant bead runs near the holes - arrow -.
- Use sealant.
- Align cap with bolts - arrows - with bolt holes.
It must be aligned exactly because it cannot be aligned after driving on.
- Drive cover on with a plastic hammer.
- Clear away leaking sealing immediately.
- Apply the rest of the drive axle grease through the ball paths into the CV joint.
- Remove any grease on the cover contact surface and on the CV joint.
- Apply sealant - hatched area - to the clean surface in the inside of the cover.
- 2 - 3 mm unbroken sealant bead dia.
- The inner sealant bead runs near the holes - arrow -.
- Use sealant.
- Place new cover on inner joint.
- Align cap with bolts - arrows - with bolt holes.
It must be aligned exactly because it cannot be aligned after driving on.
- Drive cover on with a plastic hammer.
- Clear away leaking sealing immediately.
Joints and protective joint boots must be free of grease.
- Position CV boot in outer groove - arrow 2 -.
Inner groove - arrow 1 - must remain visible identifying groove (for correct installation of joint protective sleeve).
Large and small clamps, tensioning on inner or outer joint, refer to => [ Small and Large Clamps, Tightening on Inner or Outer Joint ] Overhaul.