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

Fig 1: Identifying Joint And Triple Roller Star Splines

Courtesy of AUDI OF AMERICA, LLC

-- 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.

-- Press on joint until stop.

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

Courtesy of AUDI OF AMERICA, LLC

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

Use special tool shown in illustration.

The :T10065  can be used instead of the :40-204A  .

:40-204A  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 cap. Sealant bead: apply a continuous bead with a 2 to 3 mm diameter 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.

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.

100 mm Diameter Inner CV Joint

-- Apply 40 grams of joint grease to CV joint through ball paths.

108 mm Diameter Inner CV Joint

-- Apply 70 grams of joint grease to CV joint through ball paths.

PROCEDURE FOR BOTH CV JOINTS 

Fig 6: Coat Sealing Surface Of Cover And Cap With D 454 300 A2

Courtesy of AUDI OF AMERICA, LLC

-- Lubricate the contact surface on the cover.

-- Apply sealant "hatched surface" to clean surface on inner side of the cap. Sealant bead: apply a continuous bead with a 2 to 3 mm diameter in area of inner holes -arrow-.

-- Use Sealant.

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

Fig 7: Aligning New Cover With Bolts To Screw 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.

-- Position CV boot in outer groove -arrow 2-.

Fig 8: Identifying Outer And Inner Groove

Courtesy of AUDI OF AMERICA, LLC

Inner groove -arrow 1- remains visible "identification groove" (for correct installation of CV boot).