Inner CV joint, installing

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply sealant D 454 300 A2 - hatched surface - to clean surface on inner side of protective boot cover or cap, and. Sealant bead: unbroken, 2 to 3 mm dia., skirt area around inner holes - arrow -.

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

Slide new protective boot with cap onto drive axle.
Pack 85 g joint grease into boot.

Fig 2: Identifying Joint/Triple Roller Star Splines

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 3: Securing CV Joint From Coming Apart With Adhesive Tape

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure CV joint from coming apart, e.g. with adhesive tape - arrow -.
Press off CV joint.

NOTE:

Position ball hub with chamfer on inner diameter (splines) on drive axle.

Use special tool shown in illustration.

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

Install circlip
Press 35 g joint grease into joint through ball races.

Fig 4: Using Bolts To Align Protective Boot And Cap With Screw Holes

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 sealant immediately.

Fig 5: Aligning New Cover With Bolts To Screw Holes

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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.