Drive Axle, Disassembling And Assembling, Inner CV Joint With Cover

Special tools and workshop equipment required 

• Press Plate: VW401 
  Fig 1: Press Plate

  Courtesy of AUDI OF AMERICA, LLC
• Press Plate: VW402 
  Fig 2: Press Plate VW402

  Courtesy of AUDI OF AMERICA, LLC
• Press Piece - Rod: VW408A 
  Fig 3: Press Piece - Rod

  Courtesy of AUDI OF AMERICA, LLC
• CV Joint Press Sleeve: VW522 
  Fig 4: CV Joint Press Sleeve VW522

  Courtesy of AUDI OF AMERICA, LLC
• Press Block: 40-204A 
  Fig 5: Identifying Press Block 40 - 204 A

  Courtesy of AUDI OF AMERICA, LLC
• Sealant. Refer to the Parts Information.

Drive Off the Cover and Cap for the Inner Joint 

Fig 6: Drive Off Cover for Inner Joint

Courtesy of AUDI OF AMERICA, LLC

-- Drive off the cover -1- using the drift -A-.

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

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

Fig 7: Secure Drive Axle With Protective Covers In A Vise Clamp

Courtesy of AUDI OF AMERICA, LLC

Inner CV Joint, Removing 

Fig 8: Inner CV Joint, Removing

Courtesy of AUDI OF AMERICA, LLC

• Circlip removed

-- Position the special tool as shown:

1 -  CV Joint

A -  Press Plate: VW402 

B -  Press Piece - Rod: VW408A 

Inner CV Joint, Pressing On 

Fig 9: Inner CV Joint, Pressing On

Courtesy of AUDI OF AMERICA, LLC

-- Position the special tool as shown:

1 -  CV Joint

A -  CV Joint Press Sleeve: VW522 

B -  Press Block: 40-204A 

C -  Press Plate: VW401 

D -  Press Plate: VW402 

-- Press on joint until it stops.

-- Install the circlip.

Install the Cover for Inner Joint 

Fig 10: Install the Cover for Inner Joint

Courtesy of AUDI OF AMERICA, LLC

-- 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.

Courtesy of AUDI OF AMERICA, LLC

• 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.