Audi Workshop Service and Repair Manuals

Servicing drive shaft with 100 mm dia. inner constant velocity joint Grease filling of joints

Grease	Outer joint Ø	Inner joint Ø
G 000 603	90 mm	100 mm
Total quantity	120 g	110 g
In joint	80 g	50 g
In boot	40 g	60 g

Note Regrease joint when renewing boot.

1 -	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

2 -

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.

3 -	Profile shaft

4 -

Hose clip

q

Renew

q	Tightening → Fig. or → Fig.

5 -	Boot for outer constant velocity joint

q	Without vent hole

q	Check for splits and chafing

6 -

Hose clip

q

Renew

q	Tightening → Fig. or → Fig.

7 -	Dished spring

q	Installation position → Fig.

8 -	Spacer ring (plastic)

q	Installation position → Fig.

9 -

Circlip

q

Renew

q	Insert in groove on shaft

10 -	Boot for inner constant velocity joint

q	Without vent hole

q	Check for splits and chafing

q	Drive off constant velocity joint with a drift

q	Before fitting on constant velocity joint, coat sealing surface with D 454 300 A2

11 -

Hose clip

q

Renew

q	Tightening → Fig. or → Fig.

12 -	Lock plate

13 -	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

14 -

Circlip

q

Renew

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

15 -

Gasket

q	Adhesive surface on constant velocity joint must be free of oil and grease

16 -	Inner constant velocity joint

q	Renew only as complete unit

q	Checking → Chapter

q	Pressing off → Fig.

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

17 -	Dished spring

q	Installation position → Fig.

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 411-

t	Tube -VW 416 B-

t	Thrust plate -VW 447 H-

t	Circlip pliers -VW 161 A-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Clamp tensioner -V.A.G 1682-

t	Assembly tool -T10065-

Dismantling constant velocity joint

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

Removing and installing circlip

Knocking off cap (attached to boot) using a brass or copper drift

Pressing off inner constant velocity joint Assembling constant velocity joint

Installation position of dished spring and thrust washer at outer joint 1 -  Dished spring 2 -  Thrust washer 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.

Installation position of dished spring at inner joint 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.

–  Apply special tools as shown in illustration.   Note Chamfer on internal diameter of ball hub (splines) must face contact collar of drive shaft.

–  Fit circlip.

–  Apply sealant -hatched area- on clean inner surface of cap on CV joint boot. Sealant bead: continuous, 2...3 mm Ø. Route around inside of holes -arrow-. –  Use sealant D 454 300 A2. –  Push joint boot onto drive shaft. Drive shaft, boot and contact surface of cap must be free from grease! Take care not to damage sealant bead.

–  Using bolts -arrows-, align CV joint boot with cap 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 CV joint boot with cap using a plastic hammer. –  Remove surplus sealant immediately as it is pressed out.

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