100 mm or 107 mm Inner CV Joint, Installing

Fig 1: Identifying Installed Position Of Dished Washer (Where Applicable)

Courtesy of AUDI OF AMERICA, LLC

-- Slide the protective joint boot with the "small" clamp onto the drive axle.

-- Push the dished washer onto the drive axle, where applicable.

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

Fig 2: Identifying Joint And Triple Roller Star Splines

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

Fig 3: Securing Drive Axle With Protective Covers In A Vise Clamp

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-- Carefully position the joint on the profile shaft using the CV Joint Press Sleeve VW522 and install it all the way using a hammer.

1. Protective covers
2. Inner CV joint
3. CV Joint Press Sleeve VW522

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

-- Install a new circlip.

Fig 4: 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.

Applies to the 100 mm diameter inner CV joint

Fig 5: Coat Sealing Surface Of Cover And Cap With D 454 300 A2

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-- Apply sealant -hatched surface- to clean surface on inner side of protective joint boot cap.

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

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

-- Use Sealant .

Continuation for Both Constant Velocity Joints 

Fig 6: Aligning Cap With Bolts With Bolt Holes

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

-- 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.

Applies to the 100 mm diameter inner CV joint 

Fig 7: 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.

-- Install a new seal on the clean adhesive surface on the CV joint -arrow-. Refer to -item 15- Seal (See Figure).

Applies to the 107 mm diameter inner CV joint 

Fig 8: 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 surface- 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 .

Continuation for Both Constant Velocity Joints 

Fig 9: Aligning New Cover With Bolts To Screw 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.

Joints and protective joint boots must be free of grease.

Fig 10: Circlip Groove And Protective Boot Groove -Arrows-

Courtesy of AUDI OF AMERICA, LLC

-- Position the joint protective boot between the -arrows- into the groove -2-.

1 - ignore

2 - Positioning groove, push the joint protective boot into the groove until it engages.

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

-- Tightening clamps on inner joint