Removing the Outer CV Joint

WARNING: This page is about a different variant/trim than selected.

-- Clamp the drive axle with protective jaws in a vise.

-- Fold back the boot.

-- Align the : T10382 so that the flat side of the : T10382/1 faces the : T10382/2 .

-- Attach the : T10382 to the : VW771 .

-- Remove the CV joint from the drive axle using the : T10382 and : VW771 .

Fig 1: Identifying Outer CV Joint

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: T10382/1
: T10382/2

Outer CV Joint, Installing

Installed Location of Spring Washer and Thrust Washer on Outer 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 the new CV boot onto the drive axle if necessary.

-- Use a plastic mallet to install it on the shaft until the circlip engages.

Disassembling

-- Open both clamps at the inner joint and slide back the CV boot.

-- Remove the joint from the drive axle.

-- Remove the circlip.

Fig 3: Identifying Removal Of Circlip Using Pliers

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1 -

Pliers (Commercially Available)

or Circlip Pliers : VW161A

-- Insert the drive axle into the press.

-- Press the triple roller star off the drive axle.

Fig 4: Identifying Triple Roller Star Pressed Off From Driveshaft

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-- Pull off CV boot from shaft.

-- Clean the shaft, joint and groove for the seal.

Assembling

-- Slide the small clamp for the CV boot onto the shaft.

-- Slide the CV boot onto the shaft.

-- Slide the joint piece onto the shaft.

Triple Roller Star, Mounting

Conical Drive Axle Version

The chamfer on triple roller star faces toward shaft, this is used as an assembly aid.

-- Connect triple roller star on shaft and press on up to stop.

Fig 5: Identifying Installation Of Triple Roller Star Onto Shaft And Press Onto Stop

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-- Make sure the pressure does not increase above 3.0 t.

-- If necessary, coat the splines of the drive axle and triple roller star with Grease:G 052 142 A2 .

-- Insert the circlip while making sure it is seated correctly.

-- Press half of the drive axle grease from the repair set into the triple roller joint.

-- Slide the joint piece over rollers and secure.

-- Press the other half of the drive axle grease from the repair kit into the rear side of the triple roller joint.

-- Install the CV boot.

Triple Roller Star, Mounting

Cylindrical-Type Drive Axle

-- Connect triple roller star on shaft and press on up to stop.

Fig 6: Identifying Triple Roller Star Axle Shaft Pressed With Cylindrical Shaft

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-- Make sure the pressure does not increase above 3.0 t.

-- If necessary, coat the splines of the drive axle and triple roller star with Grease:G 052 142 A2 .

-- Insert the circlip while making sure it is seated correctly.

-- Press half of the drive axle grease from the repair set into the triple roller joint.

-- Slide the joint piece over rollers and secure.

-- Press the other half of the drive axle grease from the repair kit into the rear side of the triple roller joint.

-- Install the CV boot.

-- Push the protective boot onto the joint and mount the clamp. Refer to Figure

-- Install clamp.

Fig 7: Clamping Ear Of Clamp Placed Between Fixing Flanges From Joint

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NOTE:

For a better alignment of the multi-point socket head bolts when mounting the axle shaft, it is necessary that the clamping ear of the clamp -arrow A- is placed between the fixing flanges from the joint -arrows B-.

Tightening the Tensioning Clamps on the Larger Diameter on the Inner Joint.

Fig 8: Identifying Tensioning Clamps On Larger Diameter Of Inner Joint

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-- Attach the : VAG1682A as illustrated. When doing this, make sure that edges of the pliers are positioned in the corners -B arrows- of the clamp.

-- Tension the clamp by turning spindle with a torque wrench (without tilting the pliers).

NOTE:

The hard material of the CV boot (compared to rubber) makes it necessary to use a stainless steel hose clamp. It is only possible to tighten the hose clamp with : VAG1682A .

Tightening specification: 25 Nm.

Use torque wrench -C- with adjustment range 5 to 50 Nm (for example : VAG1331 ).

Make sure the spindle threads -A- on the pliers move easily. Lubricate with MOS 2 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 Clamp on the Outer Joint

Fig 9: Attaching CV Joint Boot Clamp Tool V.A.G 1682

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-- Attach the : VAG1682A as illustrated. When doing this, make sure that edges of the pliers are positioned in the corners -B arrows- of the clamp.

-- Tension the clamp by turning spindle with a torque wrench (without tilting the pliers).

Tightening the Tensioning Clamp on the Smaller Diameter on the Inner/Outer Joint

Fig 10: Attaching CV Joint Boot Clamp Tool VAG 1682

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