Servicing
Special Tools and Equipment
^ VW 401 thrust plate
^ VW 402 thrust plate
^ VW 407 punch
^ VW 408A punch
^ VW 522 sleeve press tool
^ 40-204 A press block
^ 3207 pressing screw
^ VAG1275 pliers
^ VAG1331 torque wrench
^ VAG 1682 CV joint boot clamp tool
Grease filling of outer constant velocity joint:
Total amount of grease: 120 grams of grease G 000 633
^ Press in approximately 80 grams of grease through the inner splines of the ball hub into the outer joint.
^ Coat approximately 40 grams and spread on the inside of the joint.
^ When replacing joint boot add more grease to joint, if necessary.
Grease filling of inner constant velocity joint:
Total amount of grease: 120 grams of grease G 000 633
^ Press in approximately 60 grams per side into joint.
^ When replacing joint boot add more grease to joint, if necessary.
1 - Clamping collar
^ Always replace
^ Tightening go to Fig. 3
2 - Joint boot for outer constant velocity joint
^ Material: Hytrel (Polyelastomere)
^ Without ventilation bore
^ Check for tears and chafe marks, replace if necessary
3 - Clamping collar
^ Always replace
^ Tightening go to Fig. 2
4 - Outer CV joint
^ Replace only as complete unit
^ Watch for different versions (with/without ABS)
^ Press off go to Fig. 1
^ Installation: Drive onto shaft using plastic hammer, until expanded securing ring contracts
5 - Hex bolt
^ 150 Nm + 90° (1/4-turn)
^ Vehicle must be standing on the ground when loosening/tightening
^ Always replace after disassembly
6 - Drive axle
^ Watch for different lengths on left/right on vehicles with automatic transmission
7 - Dished washer
^ Installation position go to Fig. 7
8 - Thrust washer
^ Installation position go to Fig. 7
9 - Snap ring
^ Always replace
^ insert in groove on shaft
10 - Joint boot for inner constant velocity joint
^ With ventilation bore
^ Check for tears and chafe marks, replace if necessary
^ Clean drive axle thoroughly, before installing the new joint boot
^ Lightly grease profile of drive axle joint boot before installing
^ Securing pos. 11 -depending on the joint boot material (hytrel or rubber)
11 - Clamping collar
^ Always replace
^ Tension clamp tightened with VAG 1682 (hytrel) or VAG 1275 rubber) depending on joint boot material go to Fig. 2 or Fig. 4
12 - Bolt with internal serrations
^ M10 x 48, 80 Nm
^ M12 x 1.5 x 55, 100 Nm
^ Always replace after disassembly
13 - Backing plate
14 - Cap carefully drive off using drift
^ Spread D 454 300 A2 on sealing surface before mounting on constant velocity joint
^ Bonding surface must be free of grease and oil!
15 - Inner constant velocity joint
^ Replace only as complete unit
^ Pressing off go to Fig. 5
^ Pressing on go to Fig 6
^ Bonding surfaces must be free of grease and oil!
16 - Snap ring
^ Always replace
^ Expand and contract using needle nose pliers
17 - Gasket
^ Replace, pull off protective foil and bond in joint.
18 - Cover
^ Vehicles as of 111 kW-engine instead of seal -post 17 -
^ Carefully drive off using drift
^ Bonding surface must be free of grease and oil!
^ Spread D 454 300 A2 on sealing surface before mounting on constant velocity joint
Fig. 1 Pressing off outside constant velocity joint
^ Clamp drive axle in vice with protective pads.
^ Fold back boot.
^ Screw special tool with M16 thread design into joint bolt until constant-velocity joint is pressed off drive axle.
Driving on joint
^ Drive onto shaft using plastic hammer, until securing ring engages.
Fig. 2 Tension large clamping collar on outer joint
^ Apply VAG1682 CV joint boot clamping pliers as shown in figure. Be sure that edges of clamping pliers are seated in corners (arrows B) of hose clamp.
^ Tighten hose clamp by turning spindle using a torque wrench (do not tilt pliers during this process).
Notes:
^ Due to the hard joint boot material (compared to rubber) the stainless steel clamp which must therefore be used can only be tensioned using VAG1682 CV joint boot clamp tool.
^ Tightening torque: 25 Nm (89 ft. lbs.)
^ Use torque wrench -C- with adjustment range 5...50 Nm (e.g. VAG1331).
^ Be sure thread of spindle -A- of clamp tool moves freely. Grease with MOS 2 grease if necessary.
^ If it does not move freely, e.g. due to dirt in thread, necessary tension of the tension clamp will not be achieved at the specified torque.
The instruction for Fig. 2 and 3 is only valid for stainless steel tension clamps!
Rubber joint bellows are clamped on with VAG1275 pliers.
Fig. 3 Tension small tension clamp on outer joint
The instruction for Fig. 2 and 3 is only valid for stainless steel tension clamps!
Rubber joint bellows are clamped on with VAG1275 pliers.
Fig. 4 Tension large tension clamp on inner joint
Fig. 5 Press off inner joint
^ Support ball hub while doing so.
^ Remove circlip before, using needle nose pliers.
^ Loosen tension clamp and push back boot.
^ Drive off cap using drift.
^ Press off joint.
^ Remove shaft from below.
Fig. 6 Press on inner joint
^ Tighten carefully using 40-204A press block, do not damage corrosion protection of drive axle.
Note: Chamfer on inner diameter of ball hub (splines) must face contact shoulder of drive axle.
^ Press on joint until it stops.
^ Install lock ring.
Fig. 7 Installation position of spring washer and of thrust washer at outer joint
1 - Dished washer
2 - Thrust washer