Overhaul

108 mm Inner CV Joint

Special tools, testers and auxiliary items required

• Thrust plate (VW 401)

• Thrust plate (VW 402)

• Punch (VW 409)

• Support sleeve (VW 522)

• Clamp (40 - 204 A)

Removing the 108 mm Inner CV Joint

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

- Drive cover down with copper or brass drift.






- Remove circlip.






- Open both clamping sleeves and remove protective joint boot from inner joint.

- Press inner CV joint off of drive shaft with special tool shown in illustration.






- Remove the CV joint boot from the drive axle.

Installing the 108 mm inner CV Joint

- Slide the joint protective sleeve with a small clamping sleeve on the drive axle.

- Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.






- Press on joint until stop.






Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.

Use special tool shown in illustration.

The (40-204 A) and the clamping surface on the drive axle must be free of oil.

Circlip must be replaced.

- Install circlip.






- Check circlip for correct seating.

- Insert 60 grams of joint grease in the boot side of the joint before installing the protective boot.

- Install the protective boot onto the inner joint.

- Apply 60 grams of joint grease to CV joint through ball paths.

- Lubricate the contact surface on the cover.

- Align new cover with bolts - arrows - to 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.

- Position CV boot in outer groove - arrow 2 -.






Inner groove - arrow 1 - must remain visible "identification groove" (for correct installation of CV boot).

Install the clamp on inner joint and clamp it.






- Use (V.A.G 1682) as shown in illustration. Be sure that edges of clamping pliers are seated in corners - arrows B - of hose 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 (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.