Drive Axle, Servicing, Attached To The Transmission Stub Shaft

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 
• Hose Clip Pliers: VAG1275A 
• Torque Wrench, 6-50Nm: VAG1331A 
• Torque Wrench 1332 40-200Nm: VAG1332 
• Clamping Pliers: VAG1682A 
• Tripod Joint Tool: T10065 
• Slide Hammer Set: VW771 
• Puller - Drive Axle: T10382 
• Three-Arm Puller : VAS251205  (previously Kukko 45-2)

Outer CV Joint, Removing 

-- 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 Puller - Driveshaft - Spindles: T10382/2  .

-- Attach the : T10382  to the : VW771  .

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

1. : T10382/1 
2. : T10382/2 

Outer CV joint, Installing 

-- Install the new circlips.

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

-- Use a plastic mallet to install it on the shaft until the circlip engages.

Disassembling 

-- Open the clamp on the inner joint and slide protective boot back from adapter.

-- Remove the joint from the drive axle.

-- Remove the circlip.

1 -  Pliers (Commercially Available)

-- Insert the drive axle into the press.

-- Press the triple roller star off the drive axle.

-- Pull off CV boot from shaft.

-- Clean the shaft, joint and groove for the seal.

Assembling 

-- Slide the small clamp for the CV boot onto the shaft.

-- Slide the CV boot onto the shaft.

-- Slide the joint piece onto the shaft.

Triple Roller Star, Conical Drive Axle, Installing: 

• The chamfer on triple roller star faces toward shaft, this is used as an assembly aid.

-- Install the triple roller star all the way onto the shaft.

-- Make sure the pressure does not increase above 3.0 t.

-- If necessary, coat the splines on the drive axle and triple roller star with Lubricant: G 052 142 A2  .

-- Insert the circlip while making sure it is seated correctly.

-- Press half of the drive axle grease from the repair set into the triple roller joint.

-- Slide the joint piece over rollers and secure.

-- Press the other half of the drive axle grease from the repair kit into the rear side of the triple roller joint.

-- Install the CV boot.

Triple Roller Star, Cylinder Drive Axle Version, Installing: 

-- Install the triple roller star all the way onto the shaft.

-- Make sure the pressure does not increase above 3.0 t.

-- If necessary, coat the splines on the drive axle and triple roller star with Lubricant: G 052 142 A2  .

-- Insert the circlip while making sure it is seated correctly.

-- Press half of the drive axle grease from the repair set into the triple roller joint.

-- Slide the joint piece over rollers and secure.

-- Press the other half of the drive axle grease from the repair kit into the rear side of the triple roller joint.

-- Slide the CV boot onto the adapter and ensure the boot engages correctly in the groove on the adapter -arrow-.

-- Mount and tension the clamp until a proper seal is guaranteed.

Tightening Clamp on the Outer Joint 

-- 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.

-- Tension the clamp by turning spindle with a torque wrench (without tilting the pliers).

• Tightening specification: 25 Nm.

Tension the Clamp on the Small Diameter 

Removing the Cap from the Triple Roller Joint 

1. Three-Arm Puller: VAS251205 
2. Press Piece - Multiple Use: VW447H 

Mounting the Cap onto the Triple Roller Joint 

1. Seal Installer - Bevel Box: T10243 

• Mount the cap far enough onto the joint until the ridge -arrow A- fits into the groove -arrow B-.