Audi Workshop Service and Repair Manuals

Renewing inner sliding constant velocity joint (100 mm or 108 mm dia.) Special tools and workshop equipment required

t  Thrust plate -VW 401-

t  Thrust plate -VW 402-

t  Press tool -VW 409-

t  Press tool -VW 412-

t  Support sleeve -VW 522-

t  Tensioner -40 - 204 A- t  Assembly tool -40-204 A- can also be used instead of tensioner -T10065-

t  Torque wrench -V.A.G 1331-

t  Clamp tensioner -V.A.G 1682- t  Circlip pliers (commercially available)

Removing inner sliding constant velocity joint (100 mm or 108 mm dia.) –  Clamp drive shaft in vice using protective jaw covers. –  Drive off cover with a copper or brass drift.

–  Drive off cover with a copper or brass drift. –  Unfasten and detach only the „small“ hose clip.

–  Remove circlip.

–  Press inner sliding constant velocity joint off drive shaft using special tools shown in illustration. –  Pull boot off drive shaft.

Installing inner sliding constant velocity joint (100 mm or 108 mm dia.) –  Push boot with „small“ hose clip onto drive shaft. –  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. Chamfer on internal diameter of ball hub (splines) must face contact collar of drive shaft. Use the special tools shown in the illustration. Assembly tool -40-204 A- can also be used instead of tensioner -T10065- Tensioner -40-204 A- or assembly tool -T10065- and clamping surface on drive shaft must be free of grease. Always renew circlip.

–  Fit circlip. –  Check that circlip is properly seated. –  Before fitting boot, pack 50 g of drive shaft grease into joint body from boot side of joint. –  Degrease contact surface for cover.

–  Apply sealant (hatched area) to clean surface on inside of boot cover. Route continuous bead of sealant (2..3 mm Ø) around inside of holes -arrow-. –  Use sealant → Electronic parts catalogue. Boot and contact surface of cap must be free of grease.

–  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. –  Remove surplus sealant immediately as it is pressed out. Inner sliding constant velocity joint (100 mm dia.) –  Pack 40 g of drive shaft grease into joint through ball races. Inner sliding constant velocity joint (108 mm dia.) –  Pack 70 g of drive shaft grease into joint through ball races.

Both types of joint (continued): –  Degrease contact surface for cover. –  Apply sealant -hatched area- to clean inner surface of cover. Route continuous bead of sealant (2..3 mm Ø) around inside of holes -arrow-. –  Use sealant → Electronic parts catalogue.

–  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. –  Remove surplus sealant immediately as it is pressed out.

–  Position boot in outer groove -arrow 2-. The inner groove -arrow 1- must remain visible („identification groove“ for correct boot assembly).

Fitting and tightening hose clips on inner joint –  Apply clamp tensioner -V.A.G 1682- as shown. Ensure jaws of tool make contact with lugs -arrows B- on hose clip. –  Tighten clip by turning spindle with torque wrench -C- (take care to keep tool straight). t  Due to the hard material of the CV joint boot (as opposed to rubber), a stainless steel hose clip is required; this can only be tightened using clamp tensioner -V.A.G 1682-. t  Tightening torque: 20 Nm. t  Use torque wrench with 5…50 Nm adjustment range (e.g. -V.A.G 1331-). t  Make sure thread of spindle on tool -A- turns 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.