Filling Joints With Grease

Fig 1: Drive Axle, Assembly Overview

Courtesy of AUDI OF AMERICA, LLC

1. 1 - Outer Constant Velocity Joint
   • Replace only as complete unit.
   • Checking, refer to OUTER CV JOINT, CHECKING .
   • Removing, refer to DRIVE AXLE WITH 100 MM DIAMETER INSERTED INNER CV JOINT .
   • Grease table, refer to DRIVE AXLE WITH 100 MM DIAMETER INSERTED INNER CV JOINT .
   • Installing, refer to DRIVE AXLE WITH 100 MM DIAMETER INSERTED INNER CV JOINT .
   • When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
2. 2 - Bolt
   • Hex bolt: 200 Nm + 180° turn. Refer to HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING .
   • Twelve point bolt: 70 Nm + 90° turn. Refer to 12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING .
   • Different versions. Allocation.
   • Always replace after removing it.
   • Before installing, clean the threads in the constant velocity joint with a tap.
3. 3 - Profile Shaft
4. 4 - Clamp
   • Replace.
   • Tensioning, refer to STAINLESS STEEL CLAMPS FOR HYTREL PROTECTIVE JOINT BOOTS, TENSIONING .
5. 5 - CV Boot for Outer CV Joint
   • Without ventilation bore.
   • Check for tears and scuffing.
6. 6 - Clamp
   • Replace.
   • Tensioning, refer to STAINLESS STEEL CLAMPS FOR HYTREL PROTECTIVE JOINT BOOTS, TENSIONING .
7. 7 - Dished Washer
   • Installed position, refer to INSTALLED LOCATION OF SPRING WASHER AND THRUST WASHER ON OUTER JOINT .
8. 8 - Spacer Ring (Plastic)
   • Installed position, refer to INSTALLED LOCATION OF SPRING WASHER AND THRUST WASHER ON OUTER JOINT .
9. 9 - Securing Ring
   • Replace.
   • Insert in shaft groove.
10. 10 - Protective Boot for Inner Constant Velocity Joint
    • Without ventilation bore.
    • Check for tears and scuffing.
    • Drive off CV joint using drift.
    • Coat the sealing surface of the CV joint with sealant -- before installing.
11. 11 - Clamp
    • Replace.
    • Tensioning, refer to STAINLESS STEEL CLAMPS FOR HYTREL PROTECTIVE JOINT BOOTS, TENSIONING .
12. 12 - Backing Plate
13. 13 - Bolt
    • Pre-tightening specification: 10 Nm and diagonally
    • Tightening specification M8: 40 Nm and diagonally
    • Tightening specification M10: 70 Nm and diagonally
    • Always replace after removing it.
14. 14 - Securing Ring
    • Replace.
    • Removing and installing using VW 161 A, refer to REMOVING SECURING RING .
15. 15 - Gasket
    NOTE:

    Bonding surface on CV joint must be free of grease and oil!

16. 16 - Inner Constant Velocity Joint
    • Replace only as complete unit.
    • Checking, refer to INNER CV JOINT, CHECKING 
    • Pressing off, refer to Pressing Off Inner Constant Velocity Joint .
    • grease → table, page FILLING JOINTS WITH GREASE .
    • Pressing on, refer to DRIVE AXLE WITH 100 MM DIAMETER BOLTED INNER CV JOINT .
    • When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
17. 17 - Dished Washer
    • Installed position, refer to INSTALLED LOCATION OF SPRING WASHER ON INNER JOINT .

Disassembling and Assembling 

Special tools and workshop equipment 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