Outer CV Joint, 88 Mm Diameter Or 98 Mm Diameter: Installing

Fig 1: Circlip (Snap Ring) & Positioning Protective Joint Boot

Courtesy of AUDI OF AMERICA, LLC

-- Slide joint protective boot onto drive axle.

• Joints and protective joint boots must be free of grease.

-- Position the protective boot between the -arrows-.

-- Place 60% of the drive axle grease distributed evenly into the inside of the CV joint.

-- Before installing joint piece, splines -A- must be lightly coated with grease used in joint.

Fig 2: Identifying Joint And Triple Roller Star Splines

Courtesy of AUDI OF AMERICA, LLC

-- Insert sealing ring in groove on axle.

-- Slide on CV joint up to sealing ring.

Fig 3: Aligning Sealing Ring At Center With Opening Upward

Courtesy of AUDI OF AMERICA, LLC

-- Align sealing ring at center with opening upward -see arrows-.

-- Install the old drive axle bolt in the joint as shown in the illustration.

Fig 4: Identifying Old Driveshaft Bolt Installed Into Joint

Courtesy of AUDI OF AMERICA, LLC

-- Drive joint onto drive axle with plastic hammer until circlip engages.

-- Install the joint protective boot onto the metal cap.

-- Bleed protective joint boot.

-- Tension clamps on outer joint.

Tightening Hose Clamp on Outer Joint

Applies to the small and large clamps.

Mount and tension stainless steel clamps using :V.A.G 1682  as illustrated.

Fig 5: Identifying Clamping Pliers VAG 1682A

Courtesy of AUDI OF AMERICA, LLC

-- When doing this, make sure that edges of clamping pliers are seated in corners -arrows B- of clamp.

-- Tighten the clamp by turning the spindle using a torque wrench (do not tilt the pliers).

• A stainless steel clamp must be used due to the hardness of the CV boot material (compared to rubber). This clamp can only be tensioned using the :V.A.G 1682  .
• Tightening Specifications: 20 Nm. 
• Use torque wrench with 5 to 50 Nm  range (xe.g. :V.A.G 1331  ).
• make sure the spindle threads on the pliers -A- move freely. Grease with MoS₂ grease if necessary.
• If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.

Mount and tension the clamp with the retaining tabs using :3340  as illustrated.

Fig 6: Close Clamp Using Pliers 3340

Courtesy of AUDI OF AMERICA, LLC

-- Engage the clamp at the first catch by hand.

-- Close the clamp using :3340  .