Rear Suspension
100 mm Diameter or 108 mm Diameter Inner CV Joint
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Sleeve-Press Tool (VW 522)
• Circlip pliers (commercially-available)
• Copper or brass drift
• Sealant the Parts Catalog
Removing a 100 mm Diameter or 108 mm Diameter Inner CV Joint
- Secure the drive axle with protective covers in a vise clamp.
- Drive cover down with copper or brass drift.
- Drive cap down with copper or brass drift.
- Only open and remove the "small" protective boot clamp.
- Remove circlip.
- Remove the inner CV joint from the drive axle using the tools illustrated.
1. Pressure plate (VW 401) or pressure plate (VW 402)
2. Punch (VW 408 A)
- Remove the CV joint boot from the drive axle.
Removing a 100 mm diameter or 108 mm diameter inner CV joint
- 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.
- Secure the drive axle with protective covers in a vise clamp.
- 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 CV joint
3. Support sleeve (VW 522)
The chamfer on inner diameter of ball hub (splines) must face and the contact collar on the drive axle.
- 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.
- Apply 2 - 3 mm diameter of unbroken bead of sealant.
- The inner sealant bead runs near the holes - arrow -.
- Use sealant the Parts Catalog.
Protective boot and cap contact surfaces must be free of grease!
- 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.
- 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.
- Apply 2 - 3 mm diameter of unbroken bead of sealant.
- The inner sealant bead runs near the holes - arrow -.
- Use sealant the Parts Catalog.
- 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.
- Slide joint protective boot onto drive axle.
Joints and protective joint boots must be free of grease.
- Position protective joint boot between - arrows -.
Ignore - 1 -.
- Make sure the protective boot is seated on the drive axle correctly.
- Tightening clamps on inner joint
Tightening Clamps on Inner Joint
• When install the large clamps, make sure the seal is between the two holes.
Depending on the version of the clamp, use the following tools:
Special tools, testers and auxiliary items required
• CV Joint Boot Clamp Tool (3340)
• CV Joint Boot Clamp Tool (V.A.G 1682)
• Torque Wrench 5-50 Nm (V.A.G 1331)
Mount and Tension Stainless Steel Clamps using (V.A.G 1682) as Illustrated.
- Use (V.A.G 1682) as shown in illustration. 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 - C - (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 (for example (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 for example dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct tightening 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).