Inner CV joint, installing

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Fig 1: Identifying Sealing Surface To Be Covered With D 454 300 A2

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply sealant - hatched surface - to clean surface on inner side of protective joint boot cap: Sealant bead: unbroken, 2 to 3 mm dia. Skirt area around inner holes - arrow -.
Use sealant D 454 300 A2 for this
Slide joint protective boot onto drive axle.

Fig 2: Identifying Joint/Triple Roller Star Splines

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.

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

Fig 3: Pressing On Inner Constant Velocity Joint

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press on joint until stop.

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

Use special tool shown in illustration.

Press block 40-204 A and clamping surfaces on drive axle must be free of grease.

Fig 4: Removing/Installing Circlip

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install circlip
Check circlip for correct seating.

Circlip must be replaced

Apply 50 g joint grease in boot.

Make sure you do not damage sealant bead.

Fig 5: Using Bolts To Align Protective Boot And Cap With Screw Holes

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using bolts - arrows - , align protective boot and cap with screw holes.

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

Drive off protective boot with cap using plastic hammer.
Clear away leaking sealing immediately.
Apply 30 g joint grease in CV joint through ball paths.

Fig 6: Identifying Seal

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Grease seal contact surface - arrow -.
Remove adhesive foil from seal and adhere to CV joint.
Align new cover with screw holes.

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

Fig 7: Pressing Cover On With Special Tool

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press cover on with special tool shown in illustration.

Fig 8: Positioning Protective Joint Boot

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position protective joint boot between - arrows -.