Servicing

Special Tools and Equipment





^ VW 401 thrust plate
^ VW 402 thrust plate
^ VW 407 punch
^ VW408A punch
^ VW 522 sleeve press tool
^ 40-204 A press block





^ VAG1682 CV joint boot clamp tool





^ VAG1331 torque wrench

Notes:
^ Only use lubricant G 052 738 A2 for constant velocity joints on rear drive axle.
^ Grease filling of inner joint: Press in half of the grease amount into joint from both sides, evenly distribute remaining grease in the cover.
^ When replacing joint boot add more grease to joint, if necessary.

Grease filling of inner constant velocity joint:
Total amount of grease: 90 grams





1 - Hex bolt 150 Nm + 90° (1/4-turn)
^ Vehicle must be standing on the ground when loosening/tightening
^ Always replace after disassembly
2 - Drive axle with outer constant velocity joint
^ The outer joint cannot be serviced.
^ Only replace complete when damaged
3 - Multipoint socket, 40 Nm
4 - Backing plate
5 - Clamping collar
^ Always replace tightening go to Fig. 3
6 - Joint boot for inner constant velocity joint
^ Check for tears and chafe marks, replace if necessary
^ Carefully drive off using drift
^ Bonding surface must be free of grease and oil!
^ Spread D 454 300 A2 on sealing surface before mounting on constant velocity joint
7 - Inner constant velocity joint
^ Replace only as complete unit
^ Pressing off go to Fig. 1
^ Pressing on go to Fig. 2
^ Bonding surfaces must be free of grease and oil
8 - Gasket
^ Replace, pull off protective foil and bond in joint.
9 - Snap ring
^ Always replace
^ Expand and contract using needle nose pliers





Fig. 1 Pressing off inner constant velocity joint
Notes:
^ First, use a drift to drive off joint boot.
^ Support ball hub.
^ Remove circlip before, using needle nose pliers.





Fig. 2 Pressing on inner constant velocity joint
^ Press on joint until it stops.
^ Install lock ring.





Fig. 3 Tension small tension clamp on outer joint

Notes:
^ Due to the hard joint boot material (compared to rubber) the stainless steel clamp which must therefore be used can only be tensioned using VAG1682 CV joint boot clamp tool.
^ Tightening torque: 25 Nm (89 ft. lbs.)
^ Use torque wrench -C- with adjustment range 5 50 Nm (e.g. VAG1331).
^ Be sure thread of spindle -A- of clamp tool moves freely. Grease with MOS 2 grease if necessary.
^ If it does not move freely, e.g. due to dirt in thread, necessary tension of clamping collar will not be achieved at the specified torque.