Drive axle with constant velocity inner joint (diameter 100 mm), servicing: Notes

Fig 1: Identifying Special Tools - Drive Axle With Constant Velocity Inner Joint (Diameter 100 mm), Servicing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required 

• Thrust plate VW 401
• Thrust plate VW 402
• Punch VW 412
• Clamp 40-204 A

• Support sleeve VW 522
• Punch VW 411

Fig 2: Identifying Hose Clamp Pliers V.A.G 1275

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Hose clamp pliers V.A.G 1275

Constant velocity joints are packed with grease G 000 603:

Grease joint again when replacing protective joint boot.

Fig 3: Exploded View Of Drive Axle With Constant Velocity Inner Joint

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Cover

• Carefully drive off using a drift Drive off cover for inner joint 
• Always replace
• Coat sealing surface with D 454 300 A2 before installing on constant velocity joint Coat cover or cap sealing surface with D 454 300 A2 
• Align cover to screw holes

2 - Circlip

• Remove and install with commercially-available circlip pliers
• Always replace

3 - Inner constant velocity joint

• Exterior diameter: 100 mm
• Replace only as a unit
• Pressing off Pressing off inner constant velocity joint 
• Pressing on Pressing on inner constant velocity joint 

• Greasing Grease quantity and type 
• Adhesive surface must be free of oil and grease
• When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in joint.

4 - Backing plate

5 - Multi-point socket head bolt

• Torque specifications:

Screw M 8: 40 Nm

Screw M10: 65 Nm

6 - Protective boot for inner CV joint with cap

• With vent hole
• Carefully drive off cap with drift
• Always replace
• In case of damage, check inner constant velocity joint → Inner constant velocity (CV) joint, checking 

• Coat sealing surface with D 454 300 A2 before installing on constant velocity joint → Figure
• Align cover to screw holes
• Protective boot/drive axle sealing surfaces must be free of grease at installation

7 - Axle shaft

8 - Outer constant velocity protective joint boot

• Without ventilation bore
• Check for tears and chafing; replace if necessary
• In case of damage, check outer constant velocity joint → Outer constant velocity (CV) joint, checking 
• Protective boot/drive axle/joint sealing surfaces must be free of grease at installation

9 - Clamp

• Always replace
• Tensioning Tighten clamp 

10 - Circlip

• Always replace
• Insert in shaft groove

11 - Outer constant velocity joint

• Exterior diameter: 88 mm
• Replace only as a unit
• Driving off Pressing off outer constant velocity joint 
• Installing: Drive onto shaft using plastic hammer until compressed circlip seats.

• Circlip must lie in joint chamfer when guiding in, guide with pliers if necessary.
• Greasing Grease quantity and type 
• When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in joint.

12 - Collar bolt

• Always replace