Drive Axle, Disassembling And Assembling, Bolted To Transmission

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Press Plate: VW401
Press Plate: VW402
Press Piece - Rod: VW408A
Press Piece - Rod: VW411
Press Piece - 37mm: VW416B
Press Piece - Multiple Use: VW447H
Circlip Pliers: VW161A
Slide Hammer Set: VW771
Puller - Drive Axle: T10382

Removing the Outer CV Joint

Fig 1: Removing The Outer CV Joint

Courtesy of AUDI OF AMERICA, LLC

-- Clamp the drive axle in a vise with jaw protectors.

-- Fold back the boot.

-- Align the : T10382 so that the flat side of the : T10382/1 faces the : T10382/2 .

-- Attach the : T10382 to the : VW771 .

-- Remove the CV joint from the drive axle using the : T10382 and : VW771 .

: T10382/1
: T10382/2

Outer CV Joint, Installing

-- Install the new circlips.

-- Slide the new CV boot onto the drive axle if necessary.

-- Drive joint onto the shaft with a plastic hammer until the circlip engages.

Drive off Cover for Inner Joint

Fig 2: Driving Cover Down With Copper Or Brass Drift

Courtesy of AUDI OF AMERICA, LLC

-- Drive the cover down using a copper or brass drift.

-- Remove the circlip.

-- Remove both clamps, and push the CV boot toward the outer joint.

-- Drive off the CV boot with a drift.

Inner CV Joint, Removing

Fig 3: Identifying Tools To Press Off Inner Constant Velocity Joint

Courtesy of AUDI OF AMERICA, LLC

-- Support the ball hub when pressing off.

Inner CV Joint, Pressing On

Fig 4: Apply Grease

Courtesy of AUDI OF AMERICA, LLC

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

-- Press on joint until it stops.

Fig 5: Identifying Tools To Press On Inner Constant Velocity Joint

Courtesy of AUDI OF AMERICA, LLC

-- Install the circlip.

NOTE:

Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.

Coat the Sealing Surface on the Cover with Sealant and Then Install It.

Fig 6: Apply Sealant

Courtesy of AUDI OF AMERICA, LLC

-- Apply sealant -hatched area- to the clean cover surface.

Sealant bead: apply a continuous bead with a 2 to 3 mm diameter in area of inner holes -arrow-.

-- Align the new cover with screws -arrows- to the screw 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 installing.

-- Drive cover on with a plastic mallet.

-- Wipe away any sealant leaking out.

CV Boot, Venting

Fig 8: Identifying Protective Joint Boot, Ventilating

Courtesy of AUDI OF AMERICA, LLC

The CV boot is frequently pressed in when placed on the joint housing. This creates a vacuum in the CV boot, which pulls a fold inward when the car is driven -arrow-.

Therefore, note the following:

-- Before tensioning the clamping sleeves, balance the pressure by raising the CV boot.

Tension the CV Boots Stainless Steel Clamps.

Fig 9: Attaching CV Joint Boot Clamp Tool V.A.G 1682

Courtesy of AUDI OF AMERICA, LLC

-- Attach the : VAG1682 as shown. When doing this, make sure that edges of the pliers are positioned in the corners -B arrows- of the clamp.

-- Tighten the clamp by turning the spindle -A- using a torque wrench (do not tilt the pliers).

Tightening specification: 20 Nm

NOTE:

Make sure the spindle threads -A- on the pliers move easily. Lubricate with MoS₂ grease, if necessary.

If difficult to tighten, for example because of dirty threads, the proper clamping force of the clamping sleeve will not be reached even when tightened to the specification.