Inner CV Joint, Installing

Fig 1: 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 2: Inner CV Joint, Pressing On

Courtesy of AUDI OF AMERICA, LLC

1 - CV Joint

A - CV Joint Press Sleeve:VW522

B - Press Block:40-204A

C - Press Plate:VW401

D - Press Plate:VW402

The Press Block:40-204A and the clamping surface on the 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 3: 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.

Fig 4: Install the Cover for Inner Joint

Courtesy of AUDI OF AMERICA, LLC

-- Apply Sealant:D 454 300 A2 on the clean surfaces on the inside of the CV boot -1- cap.

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 5: 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.

Fig 6: Install the Cover for Inner Joint

Courtesy of AUDI OF AMERICA, LLC

-- Apply Sealant:D 454 300 A2 on the clean surface on the inside of the cover -1-.

Sealant bead thickness: 2 to 3 mm.

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

-- Align the new cover with screws -arrows- to the 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 -A-.

-- 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 7: Circlip

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -item 1-.

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