Audi Workshop Service and Repair Manuals

Dismantling and assembling drive shaft with constant velocity joint VL90 or VL100

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-

t  Multi-purpose tool -VW 771-

t  Puller -T10382-

Removing outer constant velocity joint –  Clamp drive shaft in vice using protective jaw covers. –  Fold back rubber boot. –  Set up puller -T10382- so that smooth side of puller plate -T10382/1- faces towards spindles -T10382/2-. –  Assemble puller -T10382- together with multi-purpose tool -VW 771-. –  Pull CV joint off drive shaft using puller -T10382- and multi-purpose tool -VW 771-. 1 -  Puller plate -T10382/1- 2 -  Spindles -T10382/2- Driving on outer constant velocity joint

Installation position of dished spring and spacer ring on outer joint 1 -  Dished spring 2 -  Spacer ring –  Install new circlip. –  If necessary, push new joint boot onto drive shaft. –  Knock onto shaft with plastic hammer until circlip engages.

Important: Make sure that deflector ring -1- is clipped completely onto outer joint.   Note Deflector ring -1- must be flush with contact surface of outer joint -arrow-.

Pressing off inner constant velocity joint First drive rubber boot off with drift.

Pressing on inner constant velocity joint –  Press on joint as far as stop. –  Engage circlip. Chamfer on internal diameter of ball hub (splines) must face contact collar of drive shaft.

Tightening hose clip on outer joint - version 1 –  Insert lug -1- of hose clip into guide -arrow-.

–  Compress hose clip with pliers, e.g. locking pliers for Phaeton steering box -VAS 6199- until upper part -1- locks with guide -arrow-.

Tightening hose clip on outer joint - version 2 –  Apply clamp tensioner -V.A.G 1682- as shown in illustration. Ensure jaws of tool make contact with lugs -arrows B- on hose clip. –  Tighten hose clip by turning spindle with torque wrench (take care to keep tool straight).   Note 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: 25 Nm. t  Use torque wrench -C- with adjustment range 5 … 50 Nm (e.g. torque wrench -V.A.G 1331-). t  Make sure thread of spindle -A- on clamp tensioner 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.

Tightening hose clip on small diameter of inner/outer joint