Drive Axle, Disassembling And Assembling

Special tools and workshop equipment required 

• Circlip Pliers:VW161A 

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• Press Plate:VW401 

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• Press Plate:VW402 

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• Press Piece - Rod:VW408A 

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• Press Piece - Rod:VW411 

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• Press Piece - 37mm:VW416B 

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• Press Piece - Multiple Use:VW447H 

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• Clamping Pliers:VAG1682A 

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• Tripod Joint Tool:T10065 

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• Sealant. Refer to the => Electronic Parts Information (ETKA).

Outer CV Joint, Pressing Off

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

-- Fold back the boot.

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

• The drift must be precisely positioned on the CV joint ball hub.

Drive Off the Cover and Cap for the Inner Joint

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

-- Drive out the cover -1- the drive axle using a drift -A-.

-- Drive off the CV boot cap with a drift -arrow-.

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-- Remove the circlip.

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

Inner CV Joint, Removing

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-- Position the special tool as shown:

1 - CV Joint

A - Press Plate:VW401 

B - :T10065/1  from the Tripod Joint Tool:T10065 

C - Press Piece - Rod:VW408A 

D - Press Plate:VW402 

E - :T10065/4  from the Tripod Joint Tool:T10065 

Inner CV Joint, Pressing On

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• Installation position of the plate spring -1- on inner joint. 

-- Position the special tool as shown:

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1 - CV Joint

A - Press Plate:VW401 

B - :T10065/1  from the Tripod Joint Tool:T10065 

C - Press Piece - Rod:VW411 

D - Press Piece - Multiple Use:VW447H 

E - Press Piece - Multiple Use:VW454 

F - Press Plate:VW402 

G - :T10065/2  from the Tripod Joint Tool:T10065 

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

-- Press on joint until it stops.

-- Insert a new circlip.

Outer CV Joint, Installing

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• Installation position of the plate spring -1- on outer joint. 

-- Insert a new circlip.

-- Joint onto the shaft with a plastic hammer until the circlip engages.

Install the Cover for Inner Joint

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-- Apply the sealant on a clean surface of the new cover -1-.

• Sealant bead: 2 to 3 mm diameter.
• Apply the inner sealant bead near the holes -arrow- unbroken.

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

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

-- Drive cover on with a plastic mallet -A-.

-- Wipe away any sealant leaking out.

Tightening Clamp on the Outer Joint

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-- Position the Clamping Pliers:VAG1682A  -1- as shown.

• The edges of the pliers must be flush with the lock washer edges -lower arrows-.
• The threads from the spindle -A- 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

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-- Position the Clamping Pliers:VAG1682A  -A- as shown. At the same time, make sure that edges of the pliers are positioned in the corners -arrows- of the clamp -1-.

-- Tighten the clamp by turning the spindle using a torque wrench -B- (do not tilt the pliers).

• Make sure the threads on the spindle 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.