Drive Axle, Disassembling And Assembling, Drive Axle With 88 Mm Diameter Or 98 Mm Diameter CV Joint

Special tools and workshop equipment required 

• Copper or Brass Drift
• Circlip Pliers (commercially available)
• Sealant.

Removing an 88 mm Diameter or 98 mm Diameter Outer CV Joint

Fig 1: Identifying Outer CV Joint, Pressing Off

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

-- Open the clamps.

-- Slide back protective boot.

-- Remove the CV joint from the drive axle using a drift -A-.

Drift -A- must be installed exactly on the triple roller star of the CV joint.

-- Remove joint and protective joint boot.

Fig 2: Circlip

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-- Remove the circlip -1-.

Installing an 88 mm Diameter or a 98 mm Diameter Outer CV Joint

Fig 3: Circlip (Snap Ring) & Positioning Protective Joint Boot

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-- Slide joint protective boot onto drive shaft.

• 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 4: Identifying Joint And Triple Roller Star Splines

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-- Insert sealing ring in groove on shaft.

-- Slide on CV joint up to sealing ring.

Fig 5: Aligning Sealing Ring At Center With Opening Upward

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-- 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 6: Identifying Old Driveshaft Bolt Installed Into Joint

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-- 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.

Depending on the version of the clamp, use the following tools:

Special tools and workshop equipment required 

• Pliers 3340
• Clamping Pliers VAG1682A
• Torque Wrench 1331 5-50Nm VAG1331

Mount and tension stainless steel clamps using Clamping Pliers VAG1682A as illustrated.

Fig 7: Identifying Clamping Pliers VAG 1682A

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-- 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).

• The hard material of the CV boot (compared to rubber) makes it necessary to use a stainless steel hose clamp. It is only possible to tighten the hose clamp with Clamping Pliers VAG1682A.
• Tightening specification: 20 Nm.
• Use torque wrench with 5 to 50 Nm range (for example, Torque Wrench 1331 5-50Nm VAG1331).
• make sure the spindle threads on the pliers -A- move freely. Grease with MoS₂ grease if necessary.
• If the thread is tight, for example, 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 Pliers 3340 as illustrated.

Fig 8: Close Clamp Using Pliers 3340

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

-- Close the clamp using Pliers 3340.