Removing A 100 Mm Diameter Or 108 Mm Diameter Inner CV Joint: Notes

-- Slide The Protective Joint Boot With The "Small" Clamp Onto The Drive Axle.

-- Before Installing Joint Piece, Splines -A- Must Be Lightly Coated With Grease Used In Joint.

Fig 1: Identifying Joint And Triple Roller Star Splines

Courtesy of AUDI OF AMERICA, LLC

-- Press On Joint Until Stop.

Fig 2: Identifying Tools To Press On Inner Constant Velocity Joint

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Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.

Use special tool shown in illustration.

You can also use the :T10065  instead of the :40-204 A  .

:40-204 A  or :T10065  and clamping surfaces on drive shaft must be free of grease.

Circlip must be replaced.

-- Install circlip.

Fig 3: Opening Clamps And Pulling Off CV Joint Boot From Inner Joint

Courtesy of AUDI OF AMERICA, LLC

-- Check circlip for correct seating.

-- Insert 50 grams of joint grease in the boot side of the joint before installing the protective boot.

-- Lubricate the contact surface on the cover.

-- Apply sealant "hatched surface" to clean surface on inner side of protective joint boot cover. Sealant bead: Uninterrupted, apply ø 2 to 3 mm in area of inner holes -arrow-.

Fig 4: Coat Sealing Surface Of Cover And Cap With D 454 300 A2

Courtesy of AUDI OF AMERICA, LLC

-- Use sealant. Allocation, Refer To the Parts Information..

Protective boot and cap contact surfaces must be free of grease!

-- Align new cover with screws -arrows- to screw holes.

Fig 5: Aligning Cap With Bolts With Bolt Holes

Courtesy of AUDI OF AMERICA, LLC

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

-- Drive cover on with a plastic hammer.

-- Clear away leaking sealing immediately.