Axle Shaft With Constant Velocity Joint, Servicing

Special tools and equipment





- VAG 1682 Pliers
- 3340 Pliers
- VW 411 Press tool
- VW 412 Press tool
- VW 426 Tube

Grease quantity and type
Constant velocity joints are packed with grease G 000 603:





Note:
If necessary, re-grease joint when replacing CV joint boot.





1-Self-locking 12-point nut
- Tightening refer to Axle Shaft Assembly, Constant Velocity Type; Axle Shafts, Removing and Installing.
- Any paint residue and/or corrosion on thread of outer joint
must be removed before nut is installed.
- Always replace
2-Axle shaft, right (tube shaft)
3-Bolt
- 40 Nm (30 ft lb)
4-Plate
5-Hose clip
- Tightening refer to Fig. 9
- Always replace
6-Protective boot for inner CV joint
- Material: Hytrel (Polyelastomer)
- No vent hole
- Check for punctures and chafing
- Drive off CV joint using drift
7-Protective boot for inner CV
joint
- Material: Rubber
- With vent hole
- Check for punctures and chafing
- Drive off CV using drift
- Installation position for left axle shaft refer to Fig. 6
- Installation position for right axle shaft refer to Fig. 7
8-Spring washer
- Installation position refer to Fig. 3
9-inner joint
- Only replace complete
- Pressing off refer to Fig. 2
- Pressing on refer to Fig. 5
- Greasing
- Checking refer to Testing and Inspection
10-Gasket
- Adhesive surface on constant velocity joint must be free of oil and grease!
- Always replace
- Remove protective foil and stick gasket on joint.
11-Circlip
- Use VW 161 a to remove and install
12-Axle shaft, left (solid shaft)
13-Clamp
- Tensioning refer to Fig. 9
- Always replace
14-Protective boot
- Check for punctures and chafing
- Material: Hytrel (Polyelastomer)
15-Hose clip
- Tensioning with pliers VAG 1682 refer to Fig. 8
- Always replace
16-Spring washer
- Installation position refer to Fig. 4
17-Bolt
- 35 Nm (26 ft lb)
18-Heat shield
19-Thrust washer
- Installation position refer to Fig. 4
20-Circlip
- Insert in shaft groove
- Always replace
21-Outer CV joint
- Only replace complete
- Removing refer to Fig. 1
- Installing: drive on shaft to stop with plastic hammer
- Greasing
- Checking refer to Testing and Inspection





Fig. 1 Outer CV joint, removing
- Drive joint off axle shaft with firm blow from aluminium hammer.





Fig. 2 Inner CV joint, pressing off

Note:
- Support ball hub while pressing off
- Use drift to remove boot





Fig. 3 Spring washer on inner joint, installation position
1. Spring washer





Fig. 4 Spring washer and thrust washer joint outer joint, installation position
1. Spring washer
2. Thrust washer





Fig. 5 Inner CV joint, pressing on
- Press CV joint on to stop.
- Insert circlip.

Note:
Chamfer on ball hub inner diameter (splines) faces contact shoulder on axle shaft.





Fig. 6 CV joint boot (left axle), installation position
Dimension -a- = 17 mm (0.67 inch)

Note:
Before installing boot mark position, dimension -a-, (for example: paint or adhesive tape). Do not damage paint surface.





Fig. 7 Boot for CV joint (right axle), installation position
- Vent chamber -A- must seat on tube.
B-Vent hole





Fig. 8 Clamp for CV joint boot (outer), tightening
- Install VAG 1682 CV joint boot clamp tool, as shown in illustration. Ensure jaws of pliers seat in corners (arrow 13) of clamp.
- Tighten clamp by turning spindle with torque wrench (do not twist pliers).

Note:
- Due to hard material, it is only possible to tighten clamp with VAG 1682 pliers.
- Tightening torque: 20 Nm 0 5 ft lb).

- Use torque wrench -C- with 5 - 50 Nm (5 - 40 ft lb ) range (e. g. VAG 1331).
- Ensure spindle -A- is not tight. If necessary lubricate with MOS 2 grease
- If its tight e.g. dirty, required torque for clamp will not be achieved in spite of correct torque settings.





Fig.9 Clamp for CV joint boot (inner, small dia.), tightening