Drive Axle, CV Joint VL100

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Special tools and workshop equipment required

Press PlateVW401
Press PlateVW402
Press Piece - Rod VW408A
Press Piece - RodVW411
Press Piece - 37mmVW416B
Press Piece - Multiple UseVW447H
Hose Clamp PliersVAG1275
Torque Wrench 5-50NmVAG1331
Torque Wrench 40-200NmVAG1332
CV Joint Boot Clamp ToolVAG1682
Assembly ToolT10065
Slide Hammer SetVW771
PullerT10382

Removing the outer CV joint

-- Secure the drive axle with protective covers in a vise clamp.

-- Fold back boot.

-- Align the PullerT10382 so that the flat side of the PlateT10382/1 faces the SpindlesT10382/2.

-- Attach the PullerT10382 to the Slide Hammer SetVW771.

-- Remove the CV joint from the drive axle using the PullerT10382 and Slide Hammer SetVW771.

Fig 1: Identifying Outer CV Joint

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

PlateT10382/1
SpindlesT10382/2

Installing the Outer CV Joint

Fig 2: Identifying Dished Washer And Thrust Washer On Outer Joint

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Plate Spring
Thrust Ring

-- Install the new circlips.

-- Slide new CV boot onto drive axle if necessary.

-- Use a plastic hammer to install it on the shaft until the locking ring locks secure.

Fig 3: Identifying Inner Constant Velocity Joint

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Assembling

Fig 4: Identifying Dished Washer

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Plate Spring

Fig 5: Identifying Tool Assembly To Press On Inner Constant Velocity Joint

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NOTE:

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

Fig 6: Attaching CV Joint Boot Clamp Tool V.A.G 1682

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Attach CV Joint Boot Clamp ToolVAG1682 as shown in illustration below. When doing this, make sure that edges of clamping pliers are seated in corners -arrows B- of clamp.

-- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).

NOTE:

The hard material of the joint boot (compared to rubber) makes it necessary to use a stainless steel hose clamp. It is only possible to tighten the hose clamp with CV Joint Boot Clamp ToolVAG1682.

Tightening specification: 25 Nm.

Use torque wrench -C- with adjustment range 5 to 50 Nm (for example, Torque Wrench 5-50NmVAG1331).

Be sure thread of spindle -A- of clamp tool moves freely. Grease with MOS 2 grease if necessary.

If the thread is tight for example dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.

Fig 7: Attaching CV Joint Boot Clamp Tool VAG 1682

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.