Front Suspension
Drive Axle
Special tools, testers and auxiliary items required
• Thrust Piece (VW 454)
• Thrust Plate (VW 401)
• Punch (VW 408 A)
• Torque Wrench (V.A.G 1331)
• CV Joint Boot Clamp Tool (V.A.G 1682)
• Circlip Pliers (VW 161 A)
• Punch (VW 412)
• Slide Hammer - Complete Set (VW 771)
• Puller (T10382)
Perform the Following Work
- Remove drive axle. Refer to => [ Drive Axle ] Drive Axle.
Remove the Outer CV Joint
- Secure the drive axle with protective covers in a vise clamp.
- Remove the clamps.
- 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.
1. (T10382/1)
2. (T10382/2)
Check the outer joint. Refer to => [ Outer Joint, Checking ] Testing and Inspection.
Driving on Outer CV Joint
- Install the new circlips.
- Slide new CV boot onto drive axle if necessary.
- Press half of the total amount of grease from the repair kit into the joint body.
- Distribute the remaining grease from the repair kit into the joint boot.
- Drive it onto shaft with plastic hammer until securing ring engages.
Remove the Inner CV Joint
- Remove the clamps.
- First remove the outer CV joint.
- Pull off CV boot from inner joint.
- Drive off inner joint cover.
Remove circlip using (VW 161 A).
- Press off inner joint from drive axle, as depicted in illustration. Hold drive axle securely while doing so.
Inner joint cannot be disassembled for checking.
Pressing on Inner CV Joint
- Press the inner CV joint onto the drive axle as shown in the illustration.
- Install new circlip on drive axle using (VW 161 A).
- Slide new CV boot onto drive axle if necessary.
- Press half of the total amount of grease from the repair kit into the joint body.
- Distribute the remaining grease from the repair kit into the joint boot.
- Install a new cover on the inner joint.
Tensioning Clamp on Small Diameter
- Attach (V.A.G 1682) as shown in illustration. When doing this, make sure that edges of clamping pliers are seated in corners - arrows B - of clamp.
- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).
• The 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 (V.A.G 1682).
• Tightening specifications: 25 Nm.
• Use a torque wrench with an adjustment range of 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, e.g. due to dirt in thread, the required clamp tension will not be achieved at the specified torque.
Tensioning Clamp on Small Diameter
- Attach (V.A.G 1682) as shown in illustration. When doing this, make sure that edges of clamping pliers are seated in corners - arrows B - of clamp.
- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).
• The 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 (V.A.G 1682).
• Tightening specifications: 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, e.g. due to dirt in thread, the required clamp tension will not be achieved at the specified torque.