100 Mm (3.93 In.) Inner 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

Removing the Outer CV Joint:

Fig 1: CV Joint Removal

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-- 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.

Tool Installation:

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 screws -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.

Tension the CV boots stainless steel clamps.

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.