108 Mm Inner CV Joint, Servicing

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

Special tools and workshop equipment required

Circlip Pliers: VW161A
Press Plate: VW401
Press Plate: VW402
Press Piece - Rod: VW408A
CV Joint Press Sleeve: VW522
Press Block : 40-204A
Clamping Pliers: VAG1682A

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.

If Installed, Location of Spacer Ring and Spring Washer on Outer Joint:

Fig 2: Identifying Dished Washer And Thrust Washer On Outer Joint

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1 - Plate Spring

2 - Spacer ring (plastic)

Outer CV Joint with Bolt, Installing

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

Fig 3: Apply Grease

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

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

Fig 4: Drive Joint Onto Shaft With Plastic Hammer Until Circlip Engages

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Removing the Inner CV Joint

Removing the Cover:

Fig 5: Driving Cover Down With Copper Or Brass Drift

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-- Drive cover down with copper or brass drift.

Circlip, Removing and Installing:

Fig 6: Circlip

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-- Drive out CV joint boot with a drift.

-- Support ball hub when pressing off.

Fig 7: Identifying Tools To Press Off Inner Constant Velocity Joint

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Pressing on Inner CV Joint

Fig 8: Apply Grease

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

-- Press on joint until stop.

Fig 9: Identifying Tools To Press On Inner Constant Velocity Joint

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-- Install 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 10: Apply Sealant

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-- 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 new cover with screws -arrows- to screw holes.

Fig 11: Aligning New Cover With Bolts To Screw Holes

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

-- Drive cover on with a plastic hammer.

-- Wipe away any sealant leaking out.

Venting CV Boot:

Fig 12: Identifying Protective Joint Boot, Ventilating

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

Therefore, note the following:

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

Tension the CV Joint Boots Stainless Steel Clamps:

Fig 13: 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.