Drive Axle, Disassembling And Assembling, Outer CV Joint

Special tools and workshop equipment required 

• Electronic Torque Wrench 3-60Nm: VAS6583 
• Clamping Pliers: VAG1682A 
• Locking ring pliers, commercially available
• Refer to Parts Information for the sealing compound.

Outer CV Joint, Removing 

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-- Clamp the drive axle -3- in a vise with protective covers.

-- Open both clamps and remove the CV boot from the outer joint.

-- Drive out the CV joint -1- from the drive axle with a copper or brass mandrel -2- on the inner ring.

-- Remove joint and CV boot.

-- Remove the circlip -1- with the locking ring pliers.

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Outer CV Joint, Installing 

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

-- Insert the new circlip -1-.

-- 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).

-- Press half of the total amount of grease from the repair kit into the joint.

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

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-- Push the CV joint -1- up to the circlip on the drive axle -2-.

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-- Align the circlip at center with opening upward -arrows-.

-- Screw the old drive axle flange -2- into the joint -3-.

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-- Drive the joint onto the drive axle -5- plastic mallet -1- until the circlip engages.

-- Press the remaining amount of grease from the repair kit into the rear side of the joint.

-- Push the CV boot -4- on the joint -3-.

-- Bleed the CV boot.

-- Make sure the CV boot is seated on the joint correctly.

• The CV boot must fit in the groove and on joint contour.

Clamps, Tensioning 

-- Attach the : VAG1682A  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 : VAG1682A  .
• Tightening specification: 20 Nm.
• Use torque wrench with adjustment range 5 to 50 Nm (for example : VAS6583  ).
• 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.