Rear Suspension

Drive Axle

Special tools, testers and auxiliary items required

• Thrust plate (VW 401)

• Thrust plate (VW 402)

• Punch (VW 408 A)

• Punch (VW 411)

• Sleeve (VW 416 B)

• Thrust pad (VW 447 H)

• Circlip pliers (VW 161 A)

• Torque wrench (V.A.G 1331)

• Torque wrench (V.A.G 1332)

• CV joint boot clamp tool (V.A.G 1682)

• Assembly tool (T10065)

Disassembling

Outer CV Joint, Pressing Off





- Secure drive shaft with protective covers in vise clamp.

- Fold back boot.

- Drive CV joint from drive axle using a drift - A -.

Drift must be placed precisely on star of CV joint.

Driving Joint On

Installed Location: Spring Washer and Thrust Washer on Outer Joint





1 - Dished washer

2 - Thrust washer

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

Pressing Off Inner Constant Velocity Joint





- Press off CV from joint using drift.

- Remove securing ring.

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

Assembling

Installed Location of Spring Washer on Inner Joint





1. Dished washer

Pressing on Inner CV Joint





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

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).

• Torque specification: 25 Nm.

• Use torque wrench - C - with adjustment range 5 to 50 Nm (e.g. (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, e.g. due to dirt in thread, the required clamp tension will not be achieved at the specified torque.

Tensioning Clamp on Small Diameter