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)

• Tube 37 mm Dia. (VW 416 B)

• Thrust Pad (VW 447 H)

• Circlip Pliers (VW 161 A)

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

• Torque Wrench (40-200 Nm) (V.A.G 1332)

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

• Assembly Tool (T10065)

Disassembly

Removing the Outer Constant Velocity (CV) Joint





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

- Fold back the CV joint boot.

- Drive the CV joint from the axle shaft using a drift - A -.

The drift must be placed precisely on the star of the CV joint.

Installing the Outer CV Joint

- Drive the CV joint onto the axle shaft using a plastic hammer until the circlip engages.

Removing the Inner CV Joint





- Press off the CV joint using a drift.

- Remove the circlip.

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

Assembly

Installed Position of the Concave Washer on the Inner CV Joint





1. Concave washer


Pressing on the Inner CV Joint





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

Tightening the Hose Clamp on 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 tool are seated in the corners - arrows B - of the hose clamp.

- Tension the clamp by turning the spindle using a torque wrench (do not tilt the 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 5-50 Nm (for example, torque wrench (5-50 Nm) (V.A.G 1331) ).

• Be sure the threads on the spindle - A - of the tool move 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