INNER CV JOINT, 100 mm DIAMETER OR 108 mm DIAMETER WITH CAP: Removing

Fig 1: Driving Cover Down With Copper Or Brass Drift

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-- Secure the drive axle with protective covers in a vise clamp.

-- Drive cover down with copper or brass drift.

-- Drive cap down with copper or brass drift.

Fig 2: Secure Drive Axle With Protective Covers In A Vise Clamp

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-- Only open and remove the "small" protective boot clamp.

-- Remove circlip.

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

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-- Remove the inner CV joint from the drive axle using the tools illustrated.

Fig 4: Identifying Inner CV Joint From Drive Axle Using Tools

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1. :VW 401  or :VW 402 
2. :VW 408 A 

-- Remove the CV joint boot from the drive axle.

-- 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

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-- Secure the drive axle with protective covers in a vise clamp.

Fig 2: Secure Drive Axle With Protective Covers In A Vise Clamp

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-- Carefully position the joint on the profile shaft using the :VW 522  and install it all the way using a hammer.

1. Protective covers
2. Inner CV joint
3. :VW 522 

The chamfer on inner diameter of ball hub (splines) must face and the contact collar on the drive axle.

-- Install a new circlip.

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

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-- Check circlip for correct seating.

-- Add half of the drive axle grease into the joint on the boot side before installing the joint protective boot.

-- Lubricate the contact surface on the cover.

-- Apply sealant -hatched surface- to clean surface on inner side of protective joint boot cap.

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

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-- Apply 2 - 3 mm diameter unbroken bead of sealant.

-- The inner sealant bead runs near the holes -arrow-.

-- Use sealant. Allocation, refer to the Parts Information..

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

Fig 5: Aligning Cap With Bolts With Bolt Holes

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-- Align cap with bolts -arrows- with bolt holes.

-- Drive cover on with a plastic hammer.

-- Clear away leaking sealing immediately.

-- Apply the rest of the drive axle grease through the ball paths into the CV joint.

-- Remove any grease on the cover contact surface and on the CV joint.

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

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-- Remove any grease on the cover contact surface and on the CV joint.

-- Apply sealant -hatched area- to the clean surface in the inside of the cover.

-- Apply 2 - 3 mm diameter unbroken bead of sealant.

-- The inner sealant bead runs near the holes -arrow-.

-- Use sealant. Allocation, refer to the Parts Information..

-- Align cap with bolts -arrows- with bolt holes.

Fig 7: Aligning New Cover With Bolts To Screw Holes

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-- Drive cover on with a plastic hammer.

-- Clear away leaking sealing immediately.

Joints and protective joint boots must be free of grease.

Fig 8: Circlip (Snap Ring) & Positioning Protective Joint Boot

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-- Slide joint protective boot onto drive shaft.

Joints and protective joint boots must be free of grease.

-- Position protective joint boot between -arrows-.

Ignore -1-.

-- Make sure the protective boot is seated on the drive axle correctly.