Drive Axle, Disassembling And Assembling, Inner CV Joint

Special tools and workshop equipment required

Press Plate: VW401
Press Plate: VW402
Press Piece - Rod: VW409
Press Piece - Multiple Use: VW412
CV Joint Press Sleeve: VW522
Press Block : 40-204A
Torque Wrench 1331 5-50Nm: VAG1331
Locking ring pliers, commercially available
Sealant: D 454 300 A2

CAUTION:

This procedure contains mandatory replaceable parts. Refer to component overview and parts information prior to starting procedure.

Mandatory Replacement Parts

Circlip - Drive Axle
Clamp - CV Boot to Drive Axle

Inner CV Joint, Removing

Fig 1: Driving Cover Down With Copper Or Brass Drift

Courtesy of AUDI OF AMERICA, LLC

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

-- Drive down the cover with a copper or brass mandrel in direction of -arrow-.

-- Drive down the cap with a copper or brass mandrel in direction of -arrow-.

Fig 2: Secure Drive Axle With Protective Covers In A Vise Clamp

Courtesy of AUDI OF AMERICA, LLC

-- Only open and remove the "small" CV boot clamp.

-- Remove the circlip using the locking ring pliers.

Fig 3: Opening Clamps And Pulling Off CV Joint Boot From Inner Joint

Courtesy of AUDI OF AMERICA, LLC

-- Arrange the special tools as shown.

Fig 4: Pressing CV Joint Off Of Drive Axle

Courtesy of AUDI OF AMERICA, LLC

-- Press the inner CV joint off of the drive axle.

-- Remove the CV boot from the drive axle.

Inner CV Joint, Installing

Fig 5: Apply Grease

Courtesy of AUDI OF AMERICA, LLC

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

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

-- Arrange the special tools as shown.

Fig 6: Identifying Tools To Press On Inner Constant Velocity Joint

Courtesy of AUDI OF AMERICA, LLC

The : 40-204A and clamping surfaces on drive axle must be free of grease.
The chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.

-- Press on joint until it stops.

-- Install the new circlip using the locking ring pliers.

Fig 7: Opening Clamps And Pulling Off CV Joint Boot From Inner Joint

Courtesy of AUDI OF AMERICA, LLC

-- Check the seating of the circlip.

-- Apply half of the enclosed drive axle grease to the joint on the boot side before installing the CV boot.

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

-- Apply Sealant: D 454 300 A2 -cross-hatched surface- on the clean surfaces on the inside of the CV boot cap.

Fig 8: Apply Sealant

Courtesy of AUDI OF AMERICA, LLC

Sealant bead thickness: 2 to 3 mm.

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

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

Fig 9: Aligning Cap With Bolts With Bolt Holes

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

-- Drive the cap on with a plastic mallet.

-- 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 and for the CV joint.

-- Apply Sealant: D 454 300 A2 -cross-hatched surface- on the clean surface on the inside of the cover.

Fig 10: Apply Sealant

Courtesy of AUDI OF AMERICA, LLC

Sealant bead thickness: 2 to 3 mm.

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

-- Align the new cover with bolts -arrows- to the bolt holes.

Fig 11: Aligning New Cover With Bolts To Screw Holes

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

-- Drive cover on with a plastic mallet.

-- Clear away leaking sealing immediately.

-- Push on the CV boot and position it in the groove -2- between the -arrows- on the drive axle.

Fig 12: Circlip

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore item -1-.

-- Tighten clamps on inner joint. Refer to Figure.