Drive Axle, Disassembling And Assembling

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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: VAG1682A

Fig 8: Clamping Pliers - Jaws
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Tripod Joint Tool: T10065

Fig 9: Assembly Tool T10065
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Sealant. Refer to the Parts Information.

Outer CV Joint, Pressing Off

Fig 10: 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

Fig 11: Drive Off Cover for 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-.

Fig 12: Secure Drive Axle With Protective Covers In A Vise Clamp

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-- Remove the circlip.

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

Inner CV Joint, Removing

Fig 13: 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

Fig 14: Installation Position of the Plate Spring on Inner Joint

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

-- Position the special tool as shown:

Fig 15: Inner CV Joint, Pressing On

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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

Fig 16: Installation Position of the Plate Spring on Inner Joint

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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

Fig 17: 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

Fig 18: 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

Fig 19: 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.