Drive Axle, CV Joint VL107

Drive Axle, CV Joint VL107

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 408 A)

• Sleeve-Press Tool (VW 522)

• Press Block (40-204 A)

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

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Slide Hammer - Complete Set (VW 771)

• Puller (T10382)

Removing the Outer Constant Velocity (CV) Joint

- Secure the drive axle with protective covers, in a vise.

- Fold back the CV joint boot.

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

- Install the puller (T10382) to the slide hammer (VW 771/1/1).

- Remove the CV joint from the axle shaft using the puller (T10382) and slide hammer (VW 771/1/1).






1. Plate (T10382/1)

2. Spindles (T10382/2)


Installing the Outer CV Joint

Installed Position: Concave Washer and Thrust Washer on the Outer CV Joint





1 - Concave washer

2 - Thrust ring

- Install the new circlip.

- Slide the new CV joint boot onto the axle shaft, as necessary.

- Use a plastic hammer to install the boot on the shaft until the circlip locks secure.

Drive Off the Cover for the Inner CV Joint





- Remove the lock ring.

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

- Drive off the CV joint boot with a drift.

Removing the Inner CV Joint





Assembling

Pressing on the Inner CV Joint





- Press on the CV joint until seated.

- Install the lock ring.

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






- Apply an unbroken sealant bead of 2 to 3 mm in diameter on the inside of the holes - arrow - to a clean cover surface.

- Align the new cover using the bolts - arrows -.






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

- Drive the cover on using a plastic hammer.

- Wipe away any excess sealant leaking out.

Tightening the Hose Clamp for the Outer CV Joint





- Install CV joint boot clamp tool (V.A.G 1682) as shown in the illustration. Be sure that the edges of the clamp tool are seated in the corners - arrows B - of the hose clamp.

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

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

• Tightening specification: 25 Nm

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

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

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

Tensioning the Small Diameter Clamp