Driveshaft with 88 mm CV Joint, Servicing
Drive Shaft with 88 mm Outer Constant Velocity Joint and 108 mm Inner Constant Velocity Joint, Assembly Overview → Driveshaft with 100 mm and 108 mm CV Joint
Special tools, testers and auxiliary items required
- Thrust plate VW 401
- Thrust plate VW 402
- Punch VW 409
- Punch VW 412
- Support sleeve VW 522
- Clamp 40-204 A
- Assembly tool T10065 can also be used instead of clamp 40-204 A.
Special tools, testers and auxiliary items required
- Bracket 2036/1
- Sleeve 3144
- CV joint boot clamp tool V.A.G 1275
- Torque wrench V.A.G 1332
- CV joint boot clamp tool V.A.G 1682
- Assembly tool T10065
- Sealant
- Circlip pliers (commercially-available)
Inner Constant Velocity Joint, Servicing
Inner CV joint, removing
- Secure driveshaft with protective covers in vise clamp.
- Pry off cap, e.g. with a screwdriver.
- Remove seal - arrow -.
- Drive off cap from CV boot using a brass or copper mandrel.
- Clamping sleeves must not be loosened.
- Remove circlip.
- Press inner CV joint off of driveshaft with special tool shown in illustration.
- Open small clamping sleeve on driveshaft and remove protective joint boot from driveshaft.
Inner CV joint, installing
- Apply sealant -hatched surface- to clean surface on inner side of protective joint boot cover. Sealant bead: Uninterrupted, apply 2 to 3 mm diameter in area of inner holes - arrow -.
- Use sealant .
- Slide protective joint boot with small clamping sleeve on driveshaft.
- Before installing joint, coat splines - A - lightly with the same grease used in the joint.
Protective boot and cap contact surfaces must be free of grease!
- Press on joint until stop.
Chamfer on inner diameter of ball hub (splines) must face contact shoulder of drive axle.
Use special tool shown in illustration.
You can also use assembly tool T10065 instead of clamp 40-204 A.
Clamp 40-204 A or assembly tool T10065 and clamping surfaces on driveshaft must be free of grease.
Circlip must be replaced.
- Install circlip.
- Check circlip for correct seating.
- Before installing cover, apply 60 grams of driveshaft grease in CV joint through ball paths.
Make sure you do not damage the sealant bead.
- Align cap with bolts - arrows - with 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.
- Apply 60 grams of joint grease to CV joint through ball paths.
- Lubricate contact surfaces for sealing ring.
- Remove adhesive foil from seal and adhere to CV joint.
- Align new cover - A - to bolt holes.
It must be aligned exactly because it cannot be aligned after pressing on.
- Press on cap - A - using special tools depicted in illustration.
Flat steel in an appropriate size can be used instead of the bracket 2036/1.
- Position CV boot in outer groove - arrow 2 -.
Inner groove - arrow 1 - must remain visible "identifying groove" (for correct installation of protective joint boot).
Install clamp on inner joint and clamp it.
- Use CV joint boot clamp tool V.A.G 1682 as shown in illustration. Be sure that edges of clamping pliers are seated in corners - arrows B - of hose clamp.
- Tighten clamp by turning the spindle using a torque wrench - C - (do not tilt the pliers).
- A stainless steel clamp must be used due to hardness of CV boot material (compared to rubber). This clamp can only be tensioned using CV joint boot clamp tool V.A.G 1682.
- Tightening specification: 20 Nm.
- Use torque wrench with 5 to 50 Nm range (e.g. V.A.G 1331).
- Make sure the spindle threads on the pliers - A - move 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.
Inner Constant Velocity Joint, Checking
In order to replace grease in case of strong soiling, joint must be disassembled and if journal surfaces and balls must be checked for wear and damage.
Disassembling
- Ball hub and joint are paired and should be identified before removal. Do not interchange cage allocation.
- Swing ball hub and ball cage.
- Press out ball joint housing in direction of - arrows -.
- Press balls out of cage.
- Flip out ball hub from ball cage via running path of ball - arrows -.
- Check joint piece, ball hub, ball cage and balls for small broken off depressions (pitting build-up) and chafing.
- Excessive circumferential backlash in joint makes itself noticed via tip-in shock. Joint must be replaced in such cases. Flattening and running marks of balls are no reason to replace joint.
Assembling
- Insert ball hub into ball cage via two chamfers. The installation position is at random. Press balls into cage.
- Insert hub with cage and balls upright into joint piece.
- When inserting, make sure that in each case the wide gap - a - at joint piece contacts narrow gap - b - at hub after swinging in.
- Chamfer on inner diameter of wheel hub (splines) must face toward driveshaft.
- Swing in ball hub, to do so swing out hub far enough from cage - arrows - so that the balls have the distance of the running paths.
- Swing in hub with balls by pressing forcefully onto cage - arrow -.
Constant velocity joint, checking for function
Constant velocity joint is properly assembled, if ball hub can be slid back and forth by hand over whole compensation length.
- Press grease into joint body.
Drive Shaft with 88 mm Diameter Outer Constant Velocity Joint, Grease Quantities and Types.
Outer Constant Velocity Joint, Replacing
Disassembling outer CV joint
- Secure driveshaft with protective covers in vise clamp.
- Open both clamping sleeves and remove protective joint boot from outer joint.
- Strike a copper or brass drift - A - on CV joint inner race with a hammer.
- Remove joint and protective joint boot.
Outer CV joint, installing
- Slide joint protective boot onto driveshaft.
Joints and protective joint boots must be free of grease.
1 - Circlip (snap ring), must be replaced.
- Position protective joint boot between - arrows -.
- Apply 40 grams of joint grease to inside of joint.
- Install old driveshaft bolt into joint as shown in the illustration.
- Drive joint onto shaft with plastic hammer until circlip engages.
- Insert 50 grams of driveshaft grease into joint on boot side.
Install clamping sleeve on outer joint and clamp
- Install clamping sleeve on outer joint.
- Bleed protective joint boot.
- Tension clamp using pliers V.A.G 1275.
Outer Constant Velocity Joint, Checking
In order to replace grease in case of strong soiling, joint must be disassembled or if journal surface of balls must be checked for wear and damage.
Disassembling
- Mark position of ball hub to ball cage and to housing before disassembling, using electro-writer or grindstone.
- Swing ball hub and ball cage.
- Remove balls in sequence.
- Turn cage, until two rectangular windows - arrow - contact joint body.
- Lift out cage with hub.
- Swing hub segment with smaller pins into rectangular window on cage.
- Fold hub out from cage.
Checking
6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small depressions (pitting build-up) and chafing. Excessive circumferential backlash in joint makes itself noticed via tip-in shock, in such cases joint should be replaced. Flattening and running marks of balls are no reason to replace joint.
Assembling
- Insert cage with hub into joint body.
- Cage must be installed laterally correct.
- Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body must be re-established.
- Press grease into joint body.
Drive Shaft with 88 mm Diameter Outer Constant Velocity Joint, Grease Quantities and Types.