Inner CV Joint, Installing

-- Slide the CV boot with the "small" clamp onto the drive axle.

-- Apply a thin coat of grease used in the joint to the drive axle -1- splines -arrows-.

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-- Attach the Press Block:40-204A  -item 2- to the drive axle -3-.

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• The Press Block:40-204A  must grip to the bottom of the ridge -arrow- in the drive axle.

-- Tighten the nuts -4- hand-tight.

-- Insert the new circlip -1- up to the center of the splines.

-- Mount the inner CV joint with the bevel on the inner diameter of the ball hub (splines) on the drive axle shoulder.

-- Press the inner CV joint -2- on the drive axle -6-.

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1. CV Joint Press Sleeve:VW522 
2. Inner CV Joint
3. Press Block:40-204A 
4. Press Plate:VW401 
5. Press Plate:VW402 
6. Drive Axle

-- Install the new circlip -1- with locking ring pliers -2-.

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-- Check the seating of the circlip -1-.

-- Before installing the CV boot, apply half of the enclosed drive axle grease to the side of the CV boot in the joint.

-- Grease the contact surfaces for the CV boot and cap -1-.

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-- Apply the sealing compound -2- to the clean surface on the inside of the cap -1-. Refer to the appropriate Electronic Parts Information for the sealing compound.

• Sealant bead thickness: 2 to 3 mm.

-- Apply the inner sealant bead near the holes -arrow-.

-- Align the cap -1- with bolts -arrows- to the bolt holes.

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• It must be aligned exactly because it cannot be aligned after installing.

-- Drive the cap on with a plastic mallet -2-.

-- Remove any excess sealant immediately.

-- Apply the remaining drive axle grease through the ball races in the CV joint.

-- Degrease the contact surfaces for the cover -1- and for the CV joint.

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-- Apply the sealing compound -2- to the clean surface on the inside of the cover -1-. Refer to the appropriate Electronic Parts Information for the sealing compound.

• Sealant bead thickness: 2 to 3 mm.

-- Apply the inner sealant bead near the holes -arrow-.

-- Align the new cover -1- with screws -arrows- to the screw holes.

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• It must be aligned exactly because it cannot be aligned after installing.

-- Drive the cover -1- on with a plastic mallet -2-.

-- Clear away leaking sealing immediately.

• The CV boot and the drive axle must be free of grease.

-- Insert the new circlip -1-.

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-- Slide on the small clamp with the CV boot.

-- Position the CV boot in the outer groove -arrow A-.

• The inner groove -arrow B- remains visible "identification groove" (for correct installation of CV boot).

Clamps, Tensioning

Fig 1: Identifying Tensioning Clamps On Larger Diameter Of Inner Joint

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-- Attach the Clamping Pliers:V.A.G 1682A  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).

• The hard material of the CV boot (compared to rubber) makes it necessary to use a stainless steel hose clamp. It is only possible to tighten the clamp using Clamping Pliers:V.A.G 1682A  .
• Tightening specification: 20 Nm.
• Use a torque wrench with adjustment range 5 to 50 Nm (for example Electronic Torque Wrench 3-60Nm:VAS 6583  ).
• Make sure the spindle threads -A- on the pliers move easily. Lubricate with MOS 2 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.