IV - Servicing Front Axle Shaft With Constant Velocity Joint

IV - Servicing front axle shaft with constant velocity joint





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

Regrease joint, if necessary, when replacing the protective boot.
1. Self-locking 12-point nut
^ Any paint residue and/or corrosion on thread of the outer joint must be removed before the nut is installed.
^ Always replace each time after removing
2. Axle shaft, right (tube shaft)
^ Left axle shaft is shorter!
3. Multi-point socket head bolt
^ Always replace
4. Plate
5. Hose clip
^ Always replace
^ Tightening
6. Protective boot for inner constant velocity joint
^ Material: Hytrel (Polyelastomer)
^ No vent hole
^ Check for tears and chafing
^ Drive off constant velocity joint with a drift
^ Before installing on constant velocity joint coat sealing surface with D 454 300 A2
7. Protective boot for inner constant velocity joint
^ Material: Rubber
^ With vent hole
^ Check for tears and chafing
^ Drive off constant velocity joint with a drift
^ Installation position for left axle shaft
^ Installation position for right axle shaft
^ Before installing on constant velocity joint coat sealing surface with D 454 300 A2
8. Spring washer
^ Installation position
9. Inner constant velocity joint
^ Always replace
^ Pressing off, Refer to Fig. 2
^ Pressing on, Refer to Fig. 5
10. Gasket
^ Adhesive surface on constant velocity joint must be free of oil and grease!
^ Always replace
^ Pull off protective foil and stick gasket onto joint.
11. Circlip
~ Remove and install with VW 161 A
12. Cover
^ For inner constant velocity joint with diameter 107 mm
^ Carefully drive off with a drift, Refer to Fig. 10
^ Adhesive surface must be free of oil and grease!
^ Before installing on constant velocity joint coat sealing surface with D-3
13. Axle shaft, left (solid shaft)
14. Hose clip
^ Always replace
^ Tightening, Refer to Fig 9
15. Protective boot
^ Check for tears and chafing
^ Material: Hytrel (Polyelastomer)
16. Hose clip
^ Always replace
^ Tightening with pliers VAG 1682
17. Spring washer
^ Installation position
18. Thrust washer
^ Installation position
19. Circlip
^ Always replace
^ Insert in shaft groove
20. Outer constant velocity joint
^ Always replace complete
^ Removing, Refer to Fig. 1
^ Installing: drive on shaft to stop with plastic hammer
21. Hex head bolt, 35 Nm (26 ft. lbs.)
22. Heat shield





Fig. 1 Removing outer constant velocity joint

- Drive joint off axle shaft with a firm blow from an aluminum hammer.





Fig. 2 Pressing off inner constant velocity joint

Notes:
^ Use drift to remove boot
^ Support ball hub while pressing off





Fig. 3 Spring washer on inner joint, installation position

1. Spring washer





Fig. 4 Spring washer and thrust washer on outer joint, installation position

1. Spring washer
2. Thrust washer





Fig. 5 Inner constant velocity joint, pressing on

- Press constant velocity joint on to stop.
- Insert circlip.

Note:

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





Fig. 6 Installation position of joint protective boot on left axle shaft

Dimension "a" = 17 mm (0.67 inch)

Note:

Before installing boot mark position, dimension -a-, (for example paint or adhesive tape). Under no circumstances should paint surface be damaged with a sharp tool.





Fig. 7 Boot for constant velocity joint (right axle), installation position

The vent chamber -A- must seat on tube.

B - Vent hole





Fig. 8 Clamp for constant velocity joint boot (outer), tightening

- Install tension clamp VAG 1682 as shown in illustration. Make sure that the jaws of pliers seat in the corners (arrow B) of clamp.
- Tighten clamp by turning spindle with torque wrench (do not twist pliers).

Notes:

^ Due to hard material, it is only possible to tighten hose clamp with VAG 1682 pliers.
^ Tightening torque: 20 Nm (15 ft. lbs.).
^ Use torque wrench -C- with 5 to 50 Nm (3.7 - 37 ft. lbs.) range (e.g. VAG 1331).
^ Make sure spindle -A- is not tight. If necessary lubricate with MOS 2 grease
^ If it's tight e.g. dirty, required torque for the clamp will not be achieved in spite of correct tightening torque settings.





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





Fig. 10 Driving off cover for inner joint