Installing the Inner CV Joint

Fig 1: Joint/Triple Roller Star Splines

Courtesy of AUDI OF AMERICA, LLC

-- 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.

-- Press on joint until stop.

Fig 2: Tools To Press On Inner Constant Velocity Joint

Courtesy of AUDI OF AMERICA, LLC

• Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.
• The Press Block 40-204 A and clamping surfaces on drive axle must be free of grease.

-- Install circlip.

Fig 3: 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 4: 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!

-- Align new cover with bolts -arrows- to bolt holes.

Fig 5: Aligning Cap With Bolts With Bolt Holes

Courtesy of AUDI OF AMERICA, LLC

-- 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.

-- Apply sealant -hatched area- to the clean surface in the inside of the cover.

Fig 6: 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 .

-- Align new cover with bolt -arrows- to bolt holes.

Fig 7: 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 8: Circlip

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.