Removing the Outer CV Joint

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

-- Fold back boot.

-- Align the Puller T10382 so that the flat side of the Plate T10382/1 faces the Spindles T10382/2.

-- Attach the Puller T10382 to the Slide Hammer Set VW 771.

-- Remove the CV joint from the drive axle using the Puller T10382 and Slide Hammer Set VW 771.

Fig 1: Identifying Outer CV Joint

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Plate T10382/1
Spindles T10382/2

Installing the Outer CV Joint

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

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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: Driving Off Cover For Inner Joint

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-- Remove securing ring.

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

-- Drive off protective boot with drift.

Fig 4: Identifying Tools To Press Off Inner Constant Velocity Joint

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Assembling

Fig 5: Identifying Tools To Press On Inner Constant Velocity Joint

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-- Press on joint until stop.

-- Install lock ring.

-- Coat cover sealing surface with D 454 300 A2.

Fig 6: Coat Sealing Surface Of Cover And Cap With D 454 300 A2

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-- Apply unbroken sealant bead with 2 to 3 mm diameter in area of inner holes -arrow- to clean cover surface.

-- Align new cover with screws -arrows- to screw holes.

Fig 7: Aligning New Cover With Bolts To Screw Holes

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NOTE:

It must be aligned exactly because it cannot be aligned after driving on.

-- Drive cover on with a plastic hammer.

-- Wipe away any sealant leaking out.

Fig 8: Attaching CV Joint Boot Clamp Tool V.A.G 1682

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-- 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 9: Attaching CV Joint Boot Clamp Tool VAG 1682

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CV joint, Checking Function. Refer to Installing .