Drive Axle, Disassembling And Assembling, Drive Axle Inner CJ Joint (With Cap) With 100 Mm Or 108 Mm Diameter: Notes

Special tools and workshop equipment required 

• Press Plate VW401
• Press Plate VW402
• Press Piece - Rod VW408A
• CV Joint Press SleeveVW522
• Circlip Pliers (commercially available)
• Copper or Brass Drift
• Sealant.

Removing a 100 mm diameter or 108 mm diameter inner CV joint

Fig 1: Driving Cover Down With Copper Or Brass Drift

Courtesy of AUDI OF AMERICA, LLC

-- Clamp the drive axle with protective jaws 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

Courtesy of AUDI OF AMERICA, LLC

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

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

Courtesy of AUDI OF AMERICA, LLC

1. Press Plate VW401 or Press Plate VW402
2. Press Piece - Rod VW408A

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

Removing a 100 mm Diameter or 108 mm Diameter Inner CV Joint

Fig 5: Identifying Joint And Triple Roller Star Splines

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-- 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.

-- Clamp the drive axle with protective jaws in a vise clamp.

Fig 6: Secure Drive Axle With Protective Covers In A Vise Clamp

Courtesy of AUDI OF AMERICA, LLC

-- Carefully position the joint on the profile shaft using the CV Joint Press SleeveVW522 and install it all the way using a hammer.

1. Protective covers
2. Inner CV joint
3. CV Joint Press SleeveVW522

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

-- Install a new circlip.

Fig 7: Opening Clamps And Pulling Off CV Joint Boot From Inner Joint

Courtesy of AUDI OF AMERICA, LLC

-- 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 8: Coat Sealing Surface Of Cover And Cap With D 454 300 A2

Courtesy of AUDI OF AMERICA, LLC

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

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

-- Use Sealant.

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

Fig 9: Aligning Cap With Bolts With Bolt Holes

Courtesy of AUDI OF AMERICA, LLC

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

-- 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 10: Coat Sealing Surface Of Cover And Cap With D 454 300 A2

Courtesy of AUDI OF AMERICA, LLC

-- 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.

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

Fig 11: Aligning New Cover With Bolts To Screw Holes

Courtesy of AUDI OF AMERICA, LLC

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.

Joints and protective joint boots must be free of grease.

Fig 12: Circlip (Snap Ring) & Positioning Protective Joint Boot

Courtesy of AUDI OF AMERICA, LLC

-- Slide joint protective boot onto drive shaft.

Joints and protective joint boots must be free of grease.

-- Position protective joint boot between -arrows-.

Ignore item -1-.

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

-- Tightening clamps on inner joint