Drive Axle With 90 Mm Outer CV Joint, Servicing

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
Torque Wrench 1331 5-50Nm: VAG1331
Torque Wrench 1332 40-200Nm: VAG1332
Clamping Pliers: VAG1682A
Tripod Joint Tool: T10065

CV Joint, Disassembling:

Fig 1: CV Joint Removal

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Removing the outer CV joint

-- Remove the CV joint from the drive axle by hitting it with a light alloy hammer.

Circlip, Removing and Installing:

Fig 2: Circlip

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Drive Protective Joint Boot Cap Under with a Brass or Copper Drift:

Fig 3: Driving Protective Joint Boot Cap Under With Brass

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Removing the Inner CV Joint:

Fig 4: Disassembling CV Joint

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Assembling the CV Joint

Fig 5: Identifying Dished Washer And Thrust Washer On Outer Joint

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Installed location of spring washer and thrust washer on outer joint

1 -

Plate Spring

2 -

Spacer ring (plastic)

Outer CV Joint with Bolt, Installing

Fig 6: Apply Grease

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

-- Install old drive shaft bolt in joint as shown in the illustration.

Fig 7: Drive Joint Onto Shaft With Plastic Hammer Until Circlip Engages

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

Installed Location of Spring Washer on Inner Joint.

Fig 8: Identifying Dished Washer

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Pressing on Inner CV Joint

Fig 9: Apply Grease

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

-- Install tools as shown in the illustration.

Fig 10: Assembling CV Joint

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NOTE:

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

-- Install circlip using : VW161A .

Fig 11: Circlip

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-- Apply sealant -hatched surface- to clean surface on inner side of protective joint boot cap. Sealant bead: apply a continuous bead with a 2 to 3 mm diameter in area of inner holes -arrow-.

Fig 12: Apply Sealant

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-- Use sealant. Refer to the Parts Information.

-- Slide joint protective boot onto drive shaft.

Drive shaft, protective joint boot and cap contact surfaces must be free of grease.
Make sure you do not damage the sealant bead.

-- Using bolts -arrows-, align protective boot and cap with screw holes.

Fig 13: Aligning Cap With Bolts With Bolt Holes

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It must be aligned exactly because it cannot be aligned after driving on.

-- Drive off protective boot with cap using plastic hammer.

-- Clear away leaking sealing immediately.

Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning:

Fig 14: Attaching CV Joint Boot Clamp Tool V.A.G 1682

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-- Position : VAG1682A as shown in illustration. When doing this, make sure that edges of clamping pliers are seated in corners -arrows B- of clamp.

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

Tightening specification: 20 Nm

NOTE:

Be sure clamp tool spindle thread -A- moves freely. Grease with MoS₂ grease if necessary.

If the thread is tight for example, dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.

Clamps for Rubber Protective Joint Boots, Tensioning:

Fig 15: Clamping Using VAG 1275

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