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100 mm or 107 mm Inner CV Joint






100 mm or 107 mm Inner CV Joint

Special tools, testers and auxiliary items required

Pressure plate (VW 401)

Pressure plate (VW 402)

Punch (VW 408 A)

Sleeve-press tool (VW 522)

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.

- 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.






- Press inner CV joint off of drive axle with the tool shown in illustration.






1. (VW 401) or (VW 402)

2. (VW 408 A)


- Remove the disk spring from the shaft, where applicable.

- Remove the CV joint boot from the drive axle.

Installing






- Slide the protective joint boot with the "small" clamp onto the drive axle.

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

- 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. (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.

Applies to the 100 mm Diameter Inner CV Joint






- Apply sealant - hatched surface - to clean surface on inner side of protective joint boot cap.

- Apply 2 - 3 mm diameter unbroken bead of sealant.

- The inner sealant bead runs near the holes - arrow -.

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

Continuation for Both Constant Velocity Joints






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.

Applies to the 100 mm Diameter Inner CV Joint






- Remove any grease on the cover contact surface and on the CV joint.

- Install a new seal on the clean adhesive surface on the CV joint - arrow -.

Applies to the 107 mm Diameter Inner 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 unbroken bead of sealant.

- The inner sealant bead runs near the holes - arrow -.

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

Continuation for Both Constant Velocity Joints






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

1 ignore
2 Positioning groove, push the joint protective boot into the groove until it engages.

- 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 (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 (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).