Front Suspension

Drive Axle with CV Joint VL107

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 408 A)

• Support Sleeve (VW 522)

• Clamp (40 - 204 A)

• CV Joint Boot Clamp Tool (V.A.G 1682)

• Torque Wrench (V.A.G 1331)

• Slide Hammer - Complete Set (VW 771)

• Puller (T10382)

Removing outer constant velocity joint

- Secure drive axle with protective covers in vise clamp.

- Fold back boot.

- Align the (T10382) so that the flat side of the plate (T10382/1) faces the spindles (T10382/2).

- Attach the (T10382) to the (VW 771).

- Remove the CV joint from the drive axle using the puller (T10382) and (VW 771).





1. Plate (T10382/1)

2. Spindles (T10382/2)

Driving on Outer CV Joint

Installed Location of Spring Washer and Thrust Washer on Outer Joint





1 - Dished washer

2 - Thrust washer

- Drive it onto shaft with plastic hammer until securing ring engages.

Drive off Cover for Inner Joint





- Remove securing ring.

- Remove both clamps and slide joint boot toward outer joint.

- Drive out CV joint boot with a drift.

Pressing off Inner Constant Velocity Joint





Assembling

Installed Location of Spring Washer on Inner Joint





1 - Dished washer

Pressing on Inner CV Joint





- Press on joint until stop.

- Install lock ring.

- Coat cover sealing surface with (D 454 300 A2)





- Apply unbroken sealant bead with 2 to 3 mm diameter in area of inner holes - arrow - to clean cover surface.

- Align new cover with bolts - arrows - to bolt holes.





It must be aligned exactly because it cannot be aligned after driving on.

- Drive cover on with a plastic hammer.

- Wipe away any sealant leaking out.

Tightening Hose Clamp on Outer Joint





- Attach (V.A.G 1682) as shown in illustration. Be sure that edges of clamping pliers are seated in corners - arrows B - of hose clamp.

- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).

• A stainless steel clamp must be used due to hardness of CV boot material (compared to rubber). This clamp can only be tensioned using (V.A.G 1682).

• Tightening specification: 25 Nm.

• Use torque wrench - C - with adjustment range 5 to 50 Nm (for example (V.A.G 1331)).

• Be sure thread of spindle - A - of clamp tool moves freely. Grease with MOS 2 grease if necessary.

• If it does not move freely, for example due to dirt in thread, the required clamp tension will not be achieved at the specified torque.

Tensioning Clamp on Small Diameter





Outer CV joint, checking, refer to => [ Outer CV Joint, VL90 and VL100 Checking ] Outer CV Joint, VL90 and VL100 Checking

Inner CV joint, checking, refer to => [ Inner CV Joint, VL90 and VL100, Checking ] Inner CV Joint, VL90 and VL100, Checking

CV joint, checking function => [ CV joint, checking for function ] Inner CV Joint, VL90 and VL100, Checking