Drive Axle, Disassembling And Assembling

Special tools and workshop equipment required 

• Circlip Pliers: VW161A 
  Fig 1: Circlip Pliers VW 161 A

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• Press Plate: VW401 
  Fig 2: Press Plate

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• Press Plate: VW402 
  Fig 3: Press Plate VW402

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• Press Piece - Rod: VW408A 
  Fig 4: Press Piece - Rod

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• Press Piece - Rod: VW411 
  Fig 5: Press Piece - Rod

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• Press Piece - 37mm: VW416B 
  Fig 6: Press Piece - 37mm VW416 B

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• Press Piece - Multiple Use: VW447H 
  Fig 7: Press Piece - Multiple Use

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• Clamping Pliers: V. A. G 1682 A 
  Fig 8: Clamping Pliers - Jaws

  Courtesy of AUDI OF AMERICA, LLC
• Tripod Joint Tool: T10065 
  Fig 9: Assembly Tool T10065

  Courtesy of AUDI OF AMERICA, LLC

Outer CV joint, pressing off

-- Clamp the drive axle in a vise with jaw protectors.

-- Fold back the boot.

-- Push the CV joint off of the drive axle using a drift -A-.

• The drift must be installed exactly on the CV joint ball hub.

Outer CV Joint, Installing

-- Use a plastic mallet to install it on the shaft until the circlip engages.

Inner CV Joint, Removing

-- Press off the CV boot from joint using drift.

-- Remove the circlip.

-- Remove both clamps, and push the CV boot toward outer joint.

Plate spring installation position on the inner and outer joint

1. Plate Spring

-- Press on joint until it stops.

-- Install the circlip.

Inner CV Joint, Pressing On

• The chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.

Tightening clamp on the outer joint

-- Attach the Clamping Pliers: V. A. G 1682  as shown.

• The edges of the pliers must be flush with the lock washer edges -B arrows-.
• The spindle threads must turn easily. If necessary, coat with MoS₂ lubricating grease.

TIP: 

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.

-- Tension the clamp by turning the spindle -A- with the torque wrench. Do not tilt the clamping pliers during this.

• Tightening specification: 25 Nm.

Tension the clamp on the small diameter

-- Attach the Clamping Pliers: V. A. G 1682A  as shown. At the same time, make sure that edges of the pliers are positioned in the corners -B arrows- of the clamp.

-- Tighten the clamp by turning the spindle -A- using a torque wrench -C- (without tilting the pliers).

• Make sure the spindle threads -A- on the pliers move easily. Lubricate with MoS₂ 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.

• Tightening specification: 25 Nm.