Overhaul
100 mm Inner CV Joint
Filling the Joints with Grease
• Grease joint again when replacing protective joint boot.
1 - Outer CV Joint
• Replace only as complete unit.
• Checking, refer to => [ Outer CV Joint, Checking ] Outer CV Joint, Checking.
• Removing.
• Greasing.
• Installing.
• When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
2 - Bolt
• Always replace if removed.
• There are different versions. Allocation, refer to the Electronic Parts Catalog (ETKA).
• Bolt: 200 Nm + 180° turn. Loosening and tightening, refer to => [ Drive Axle Hex Bolt Connection, Loosening and Tightening ] Drive Axle Hex Bolt Connection, Loosening and Tightening.
• Twelve-point bolt with ribs: 70 Nm + 90° turn. Loosening and tightening, refer to => [ Drive Axle Twelve-Point Bolt with Ribs, Loosening and Tightening ] Drive Axle Twelve-Point Bolt With Ribs, Loosening and Tightening.
• Twelve-point bolt without ribs: 200 Nm + 180° turn. Loosening and tightening, refer to => [ Drive Axle Twelve-Point Bolt without Ribs, Loosening and Tightening ] Drive Axle Twelve-Point Bolt Without Ribs, Loosening and Tightening.
• Before installing, clean the threads in the CV joint with a tap.
3 - Profile Shaft
4 - Clamp
• Replace
• Tensioning.
5 - CV Boot for Outer CV Joint
• Without ventilation bore.
• Check for tears and scuffing.
6 - Clamp
• Replace
• Tensioning.
7 - Dished Washer
8 - Spacer Ring (Plastic)
9 - Securing Ring
• Replace
• Insert in shaft groove.
10 - Protective Boot for Inner CV Joint
• Without ventilation bore.
• Check for tears and scuffing.
• Drive off CV joint using drift.
• Coat the sealing surface with D 454 300 A2 before installing it on the CV joint.
11 - Clamp
• Replace
• Tensioning.
12 - Backing Plate
13 - Socket Head Bolt
• Always replace if removed
• Pre-tightening specification: 10 Nm and diagonally
• Tightening specification M8: 40 Nm and diagonally
• Tightening specification M10: 70 Nm and diagonally
14 - Securing Ring
• Replace
• Removing and installing using (VW 161 A).
15 - Gasket
• Bonding surface on CV joint must be free of grease and oil!
16 - Inner CV Joint
• Replace only as complete unit.
• Checking, refer to => [ Inner CV Joint, Checking ] Inner CV Joint, Checking.
• Pressing off.
• Greasing.
• Pressing on.
• When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
17 - Dished Washer
Special tools, testers and auxiliary items required
• Thrust plate (VW 401)
• Thrust plate (VW 402)
• Punch (VW 408 A)
• Punch (VW 411)
• Sleeve (VW 416 B)
• Thrust pad (VW 447 H)
• Locking ring pliers (VW 161 A)
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1332)
• CV joint boot clamp tool (V.A.G 1682)
• Assembly tool (T10065)
CV Joint, Disassembling
Removing the Outer CV Joint
- Remove the CV joint from the drive axle by hitting it with a light alloy hammer.
Circlip, Removing and Installing
Drive Protective Joint Boot Cap Under with a Brass or Copper Drift
Removing the Inner CV Joint
Assembling the CV Joint
Installed Location of Spring Washer and Thrust Washer on Outer Joint
1 - Dished washer
2 - Thrust washer
Outer CV Joint with Bolt, Assembling
- Before installing joint piece, splines - A - must be lightly coated with grease used in joint.
- Install old drive axle bolt in joint as shown in the illustration.
- Drive joint onto axle with plastic hammer until circlip engages.
Installed Location of Spring Washer on Inner Joint
Pressing On Inner CV Joint
- Before installing joint piece, splines - A - must be lightly coated with grease used in joint.
- Install tools as shown in the illustration.
• Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.
- Install circlip.
- Apply sealant - hatched surface - to clean surface on inner side of protective joint boot cap. Sealant bead: unbroken, 2 to 3 mm diameter Skirt area around inner holes - arrow -.
- Use sealant D 454 300 A2 for this.
- Slide joint protective boot onto drive axle.
• Drive axle, protective joint boot and cap contact surfaces must be free of grease.
• Make sure you do not damage the sealant bead.
- Using bolts - arrows -, align protective boot and cap with bolt holes.
• It must be aligned exactly because it cannot be aligned after driving on.
- Drive off protective boot with cap using plastic hammer.
- Clear away leaking sealing immediately.
Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning
- Position (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 hose clamp by turning spindle - A - using a torque wrench (do not tilt clamping pliers).
• Tightening specifications: 20 Nm
• Be sure thread of spindle in clamping pliers moves freely. Grease with MOS 2 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.
Clamps for Rubber Protective Joint Boots, Tensioning
