Drive Axle, Disassembling And Assembling

WARNING: This page is about a different car, the 2023 Volkswagen Atlas. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Axle Shaft Assembly

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Special tools and workshop equipment required

Press Plate:VW401
Press Plate:VW402
Press Piece - Rod:VW408A
Press Piece - Rod:VW411
Press Piece - 37mm:VW416B
Press Piece - Multiple Use:VW447H

Fig 2: Identifying Special Tools (Circlip Pliers VW161A)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Special tools and workshop equipment required

Circlip Pliers:VW161A
Torque Wrench, 6-50Nm:VAG1331A
Torque Wrench, 40-200Nm:VAG1332A
Clamping Pliers:VAG1682A
Tripod Joint Tool:T10065

Disassembling

Outer CV Joint, Pressing Off

Fig 3: Identifying Outer CV Joint, Pressing Off

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Clamp the drive axle in a vise with jaw protectors.

-- Remove the clamp.

-- 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.

Driving Joint on

Installed Position, Plate Spring on the Outer Joint

Fig 4: Identifying Dished Washer

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Plate Spring

-- Insert a new circlip.

-- Drive the joint onto the shaft using a plastic hammer until the circlip locks into place.

Only for CV joint VL90

Drive Off Cover for Inner Joint

Fig 5: Driving Off Cover For Inner Joint

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Continuation for All Drive Axles

-- Drive in the CV boot using a drift from the inner joint.

-- Remove the circlip.

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

Inner CV Joint, Removing

Fig 6: Disassembling CV Joint

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Assembling

Installation Position of the Plate Spring on Inner Joint

Fig 7: Identifying Dished Washer

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Plate Spring

Inner CV Joint, Pressing On

Fig 8: Assembling CV Joint

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

-- Press on joint until it stops.

-- Install the circlip.

Only for CV Joint VL90

Fig 9: Aligning New Cover With Bolts To Screw Holes

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

It Must be Aligned Exactly Because it Cannot be Aligned After Installing.

-- Drive cover on with a plastic mallet.

Continuation for All Drive Axles

Tightening Clamp on the Outer Joint

Fig 10: Attaching CV Joint Boot Clamp Tool V. A. G 1682

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Attach the :VAG1682A as shown. 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 clamp using :VAG1682A .

Tightening specification: 25 Nm.

Use the torque wrench 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.

Tension the Clamp on the Small Diameter

Fig 11: Attaching CV Joint Boot Clamp Tool VAG 1682

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Attach the :VAG1682A as shown. 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 clamp using :VAG1682A .

Tightening specification: 25 Nm.

Use the 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.