Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ 3207 Pressure spindle
• ◆ 40-204 A Tensioner
• ◆ VW 161 A Circlip pliers
• ◆ VW 401 Pressure plate
• ◆ VW 402 Pressure plate
• ◆ VW 411 Press tool
• ◆ VW 412 Press tool
• ◆ VW 522 Support sleeve
• ◆ V.A.G 1275 Hose clamp pliers

Quantities and type of grease

Constant velocity joints are filled with high-temperature grease.

=> Parts List

Re-grease joint if necessary on replacing boot.

• Circlip
• ◆ Always replace
• ◆ Removing and fitting with circlip pliers VW 161 A => Fig.4

• Gasket
• ◆ Replace; pull off backing and bond into joint
• Inner constant velocity joint
• ◆ OD: 100 mm
• ◆ Replace only as complete assembly
• ◆ Pressing off => Fig.2
• ◆ Pressing on => Fig. 3
• ◆ Lubricating
• ◆ Checking => Page 42-130
• Dished washer
• ◆ Installation position => Fig. 6

• Boot for inner constant velocity joint
• ◆ Check for cracks and abrasion
• ◆ Drive off with mandrel
• ◆ Checking inner constant velocity joint if boot damaged => Page 42-130
• ◆ Coat sealing surface with D 454 300 A2 before attaching to constant velocity joint
• ◆ Before fitting, align screw holes of inner constant velocity joint and inner boot
• ◆ On assembly, boot/drive shaft sealing surfaces must be free from grease
• Drive shaft
• ◆ Same length on left and right

• Boot for outer constant velocity joint
• ◆ Check for cracks and abrasion and replace if necesssary
• ◆ Checking outer constant velocity joint if boot damaged => Page 42-127
• ◆ On assembly, boot/drive shaft/joint sealing surfaces must be free from grease
• Clamp
• ◆ Replace
• ◆ Tensioning => Fig. 1
• Dished washer
• ◆ Large ø (concave side) makes contact with thrust ring
• ◆ Installation position => Fig. 5
• Spacer ring (plastic)
• ◆ Installation position => Fig.5

• Circlip
• ◆ Replace
• ◆ Insert in shaft groove
• Outer constant velocity joint
• ◆ OD: 89 mm
• ◆ Replace only as complete assembly
• ◆ Pressing off =>Fig. 7
• ◆ Checking => Page 42-127
• ◆ Installing: Drive onto shaft with plastic-headed hammer until circlip engages in annular groove of constant velocity joint
• ◆ Lubricating => Page 42-118

→ Fig.1    Tensioning hose clamp or clamp

→ Fig.2     Pressing off inner constant velocity joint

Notes:

• ◆ Use mandrel to drive off boot beforehand.
• ◆ Support ball hub.

→ Fig.3    Pressing on inner constant velocity joint

Note:

Chamfer at ID of ball hub (splines) must face contact collar of drive shaft.

• ‒ Press on joint as far as it will go.
• ‒ Engage circlip.

→ Fig.4    Removing/fitting circlip

Fig.5    → Installation position of spacer ring and dished washer (wheel end)

•     1 -    Dished washer
•     2 -    Spacer ring (plastic)

→ Fig.6    Fitting dished washer in correct position

→ Fig.7    Pressing off outer constant velocity joint

• ‒ Clamp drive shaft with soft jaws in vice.
• ‒ Detach clamp and push back bellows.
• ‒ Screw pressure spindle -3207- with M14 thread into joint pin until constant velocity joint is pressed off drive shaft.