I - Front Axle Shaft With Constant Velocity Joint, Servicing
I - Front axle shaft with constant velocity joint, servicing
Special tools, testers and auxiliary items required
^ Thrust plate VW401
^ Thrust plate VW402
^ Punch VW408A
^ Punch VW411
^ Sleeve VW41 6B
^ Thrust pad VW447H
Special tools, testers and auxiliary items required
^ Circlip pliers VW161A
^ Torque wrench V.A.G. 1331
^ Torque wrench V.A.G. 1332
^ CV joint boot clamp tool V.A.G. 1682
^ Assembly tool T10065
Grease quantity and type
Filling the axle shaft with high temperature grease; Refer to Parts Supplier
When replacing the protective boot grease joint, if necessary.
1. Self-locking 12-point nut
^ Always replace
2. Outer constant velocity joint
3. Circlip
^ Always replace
^ Insert in shaft groove
4. Thrust washer
5. Spring washer
6. Hose clamp
7. Protective joint boot
^ Check for tears and chafing
^ Material: Hytrel (Polyelastomer)
8. Hose clamp
9. Axle shaft
10. Hose clamp
11. 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 D454300A2
12. Protective boot for inner constant velocity joint
13. Plate
14. Multi-point socket head bolt
15. Spring washer
16. Inner constant velocity joint
^ Replace only as a unit
^ Pressing off inner constant velocity joint
^ Pressing on inner constant velocity joint
17. 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.
18. Circlip
^ Remove and install with VW161 A
19. Hex bolt, 35 Nm (26 ft. lbs.)
20. Protective cover
Removing outer constant velocity joint
- Drive joint off axle shaft with a firm blow from a plastic hammer.
Pressing off inner constant velocity joint
Note: Use drift to remove boot
Installing spring washer on inner joint
1 - Spring washer
Installing spring washer and thrust washer on outer joint
1 - Spring washer
2 - Thrust washer
Pressing on inner constant velocity joint
- 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 drive shaft.
Installing joint protective boot on left axle shaft
Dimension - a - = 17 mm
Before installing boot mark position, measure - a - (for example paint or adhesive tape). Under no circumstances should paint surface be damaged with a sharp tool.
Installing boot for constant velocity joint (right axle)
The vent chamber - A - must seat on tube.
B - Vent hole
Tightening clamp for constant velocity joint boot (outer)
- Install tightening clamp V.A.G. 1682 as shown in illustration. Make sure that the jaws of the pliers seat in the corners - arrows B - of the hose clamp.
- Tighten hose clamp by turning the spindle with a torque wrench (do not twist pliers).
Note:
^ Due to hard material of the joint boot (compared to rubber) makes it necessary to use a stainless steel hose clamp, it is only possible to tighten the hose clamp with clamping device V.A.G. 1682.
^ Tightening torque: 25 Nm (18.5 ft. lbs.).
^ Use torque wrench - C - with a range of 5...50 Nm (3.7 - 37 ft. lbs.) (e.g. V.A. G1331 ).
^ Make sure the spindle thread - A - is not tight. If necessary lubricate with grease MOS 2.
^ If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct tightening torque settings.
Tightening clamp for CV joint boot (inner, small dia.)
Outer constant velocity joint, checking
Joint must be disassembled to replace dirty grease or for checking the balls and ball tracks for wear and damage.
Removing
- Before disassembling mark ball hub position in relation to the ball cage and housing with an electric scribe or oil stone.
- Swivel ball hub and ball cage.
- Remove balls one after another.
- Turn cage until the two rectangular windows - arrow - are aligned with the joint housing.
- Lift out cage together with hub.
- Swing segment of hub into rectangular cage opening.
- Tilt hub out of cage.
Note: The 6 balls of each joint belong to one tolerance group. Check stub axle, hub, cage and balls for small indentations (pitting) and signs of seizure. Excessive backlash in joint will be noticed as a knock during load changes, in such cases the joint must be replaced. Polished areas and ball track marks are not a reason for changing joint.
Installing
- Press half of the total amount of grease 40 grams (1.4 oz.) into the joint body.
- Install cage with hub in the joint housing.
- Press in the balls one after another from opposite sides whereby the original position of the hub to cage and joint housing must be restored.
- Install new circlip in hub.
- Distribute remaining grease in constant velocity joint boot.
Inner constant velocity joint, checking
When checking the balls and ball tracks for wear and damage the joint should be disassembled to replace dirty grease.
Removing
- Swivel ball hub and ball cage.
- Press out ball joint housing in direction of - arrow - .
- Press balls out of cage.
Note: The ball hub and joint are paired. Must not be interchanged.
- Tilt ball hub out of ball cage over ball track - arrow - .
- Check joint housing, ball hub, ball cage and balls for indentations (pitting) and signs of seizure.
Note: Excessive backlash in joint will be noticed as a knock during load changes. In such cases the joint must be replaced. Polished areas and ball track marks are not a reason for replacing joint.
Installing
- Insert ball hub over both chamfers into the ball cage. The hub can be installed in any position. Press balls into the cage.
- Insert hub with cage and balls at right angle to the joint.
- When inserting make sure that the wide space - a - on joint housing is aligned with the narrow space - b - on the hub after swiveling in.
^ Chamfer on inner diameter of ball hub (splines) must face larger diameter of joint housing.
- Install ball hub, whereby the hub must be swiveled out of the cage - arrows - far enough to allow the balls to fit into the ball tracks.
- Press cage firmly - arrow - until hub swings fully in position.
Check operation of constant velocity joint:
The constant velocity joint is correctly assembled when the ball hub can be moved by hand backward and forward over its entire axial movement range.