Drive Axle, Disassembling And Assembling, Drive Axle With 88 Mm Or 100 Mm Diameter CV Joint: Notes

Special tools and workshop equipment required 

• Pliers 3340
• Circlip Pliers (commercially available)
• Sealant.

Removing an 88 mm diameter or 100 mm diameter outer CV joint

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

-- Open The Clamp Using Pliers 3340

Fig 1: Inserting Pliers 3340 At Back Of Hose Clamp

Courtesy of AUDI OF AMERICA, LLC

Insert the Pliers 3340 at the rear of the clamp, as shown in the illustration.

-- Slide back protective boot.

-- Strike a copper or brass drift -A- on CV joint inner race with a hammer.

Fig 2: Hitting Copper Or Brass Mandrel Onto Inner Ring Of Constant Velocity Joint

Courtesy of AUDI OF AMERICA, LLC

-- Remove joint and protective joint boot.

-- Remove the circlip.

Installing an 88 mm diameter or a 100 mm diameter outer CV joint

Fig 3: 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-.

1 -

Circlip (snap ring), must be replaced.

88 mm Diameter Outer CV Joint

-- Apply 40 grams of joint grease to inside of joint.

100 mm Diameter Outer CV Joint

-- Apply 70 grams of drive shaft grease to the inside of the joint.

Continuation for Both Constant Velocity Joints

Fig 4: Identifying Joint And Triple Roller Star Splines

Courtesy of AUDI OF AMERICA, LLC

-- Before installing joint piece, splines -A- must be lightly coated with grease used in joint.

-- 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

Courtesy of AUDI OF AMERICA, LLC

-- 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

Courtesy of AUDI OF AMERICA, LLC

-- Drive joint onto drive axle with plastic hammer until circlip engages.

-- Insert 50 grams of drive axle grease into joint on boot side.

-- Install the protective boot on the outer joint.

-- Bleed protective joint boot.

-- Make sure the protective boot is seated on the joint correctly.

-- Protective joint boot must fit in groove and on joint contour.