Audi Workshop Service and Repair Manuals

Servicing drive shaft with 108 mm dia. inner constant velocity joint Grease filling of joints

Grease	Outer joint Ø	Inner joint Ø
G 000 603	98 mm	108 mm
Total quantity	120 g	130 g
In joint	80 g	60 g
In boot	40 g	70 g

Note Regrease joint when renewing boot.

1 -

Bolt

q	Always renew if removed

q	Different versions; for correct version refer to → Electronic parts catalogue

q	Hexagon bolt = 200 Nm + turn 180° further; loosening and tightening → Chapter

q	Twelve-point ribbed bolt = 70 Nm + turn 90° further; loosening and tightening → Chapter

q	Twelve-point bolt without ribbing = 200 Nm + turn 180° further; loosening and tightening → Chapter

q	Before securing, clean the threads in the CV joint using a thread tap.

Vehicle must be standing on the ground when tightening

2 -	Outer constant velocity joint

q	Renew only as complete unit

q	Checking → Chapter

q	Removing → Fig.

q	Greasing ⇒ see table → Anchor

q	Installing → Anchor

q	Grease splines on drive shaft lightly with grease used in joint when fitting joint onto drive shaft

3 -

Circlip

q	Always renew if removed

q	Insert in groove on shaft

4 -	Spacer ring (plastic)

q	Installation position → Fig.

5 -	Dished spring

q	Installation position → Fig.

6 -

Hose clip

q	Always renew if removed

q	Tightening → Fig. or → Fig.

7 -	Boot for outer constant velocity joint

q	Without vent hole

q	Check for splits and chafing

8 -

Hose clip

q	Always renew if removed

q	Tightening → Fig. or → Fig.

9 -	Profile shaft

10 -

Hose clip

q	Always renew if removed

q	Tightening → Fig. or → Fig.

11 -	Boot for inner constant velocity joint

q	Check for splits and chafing

12 -	Multi-point socket head bolt

q	Always renew if removed

q	Initial tightening torque: 10 Nm in diagonal sequence

q	Tightening torque, M8: 40 Nm in diagonal sequence

q	Tightening torque, M10: 70 Nm in diagonal sequence

13 -	Lock plate

14 -

Hose clip

q	Always renew if removed

q	Tightening → Fig. or → Fig.

15 -	Inner constant velocity joint

q	Renew only as complete unit

q	Checking → Chapter

q	Pressing off → Anchor

q	Greasing ⇒ see table → Anchor

q	Pressing on → Anchor

q	Grease splines on drive shaft lightly with grease used in joint when fitting joint onto drive shaft

16 -

Circlip

q	Always renew if removed

q	Removing and installing with -VW 161 A- → Fig.

17 -

Cover

q	Always renew if removed

q	Drive off constant velocity joint with a drift

q	Apply sealant D 454 300 A2 between joint and cover → Fig..

Removing outer constant velocity joint –  Drive joint off drive shaft with a firm blow from an aluminium hammer.

Installation position of spacer ring and dished spring on outer joint 1 -  Dished spring 2 -  Spacer ring (plastic)

Installing outer constant velocity joint with bolt –  Grease splines -A- on drive shaft lightly with grease used in joint before fitting joint body onto drive shaft.

–  Screw old bolt into CV joint as shown. –  Use plastic-headed hammer to drive joint onto shaft until circlip engages. Pressing off inner constant velocity joint

Detaching cover –  Drive off cover with a copper or brass drift.

Removing and installing circlip –  Use drift to drive off boot.

–  Support ball hub while pressing off.

Pressing on inner constant velocity joint –  Grease splines -A- on drive shaft lightly with grease used in joint before fitting joint body onto drive shaft.

–  Press on joint as far as stop. –  Fit circlip.   Note Chamfer on internal diameter of ball hub (splines) must face contact collar of drive shaft.

Applying sealant D 454 300 A2 to cover and installing cover –  Apply sealant -hatched area- to clean surface of cover. t  Route continuous bead of sealant (2..3 mm Ø) around holes on the inside -arrow-.

–  Using bolts -arrows-, align new cover in relation to bolt holes. The alignment must be very accurate, because no further alignment is possible once the part has been hammered on. –  Drive on cover using a plastic hammer. –  Wipe off surplus sealant.

Venting rubber boot The CV joint boot is often squashed when it is installed on the joint body. This creates a partial vacuum inside the boot, which draws in a fold -arrow- whilst driving. For this reason, please note the following: –  Before tightening the hose clips, vent the boot to equalise pressure by briefly lifting the lip.

Tightening stainless-steel hose clips for Hytrel boots –  Apply clamp tensioner V.A.G 1682 as shown. Ensure jaws of tool make contact with lugs -arrows B- on hose clip. –  Tighten hose clip by turning spindle -A- with torque wrench (take care to keep clamp tensioner straight). t  Tightening torque: 20 Nm   Note t  Make sure thread of spindle on clamp tensioner moves freely. Lubricate with MoS2 grease if necessary. t  If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clip when the specified tightening torque is applied.

Tightening hose clip for rubber boot