Audi Workshop Service and Repair Manuals

Servicing drive shaft (version with internal splines on inner sliding CV joint) Grease filling of joints

Grease	Outer joint	Inner joint
Total quantity	140 g	140 g

1 -

Bolt

q	Different versions possible. For correct version refer to → Electronic parts catalogue „ETKA“

q	Always renew if removed

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.

2 -	Outer constant velocity joint

q	Renew only as complete unit

q	Removing → Fig.

q	Distribute grease filling through ball races → Anchor

q	Installing: drive onto shaft as far as stop using a plastic head hammer

q	Checking → Chapter

3 -

Circlip

q	Always renew if removed

q	Insert in groove on shaft

4 -

Hose clip

q	Always renew if removed

q	Tightening → Fig.

5 -

Boot

q	Check for splits and chafing

q	Material: Hytrel (polyelastomer)

6 -

Hose clip

q	Always renew if removed

q	Tightening → Fig.

7 -	Drive shaft

8 -

Hose clip

q	Always renew if removed

q	Tightening → Fig.

9 -	Boot for sliding constant velocity joint

q	Material: Hytrel (polyelastomer)

q	Check for splits and chafing

10 -

Circlip

q	Always renew if removed

q	Insert in groove on shaft

11 -

Hose clip

q	Always renew if removed

q	Tightening → Fig.

12 -	Sliding constant velocity joint

q	Renew only as complete unit

q	Removing → Fig.

q	Distribute grease filling through ball races → Anchor

q	Installing: drive onto shaft as far as stop using a plastic head hammer

13 -	Protective cap

q	Detaching → Fig.

q	Driving on → Fig.

Removing outer constant velocity joint –  Clamp drive shaft in vice using protective jaw covers. –  Unfasten both clips and detach boot from outer joint. –  Use hammer to tap copper or brass drift -A- against inner race of constant velocity joint. –  Detach joint and boot.

Installing outer joint Boot and drive shaft must be free from grease. –  Always renew circlip -1-. –  Push on small hose clip with joint boot and bring boot into position on drive shaft.

–  Position boot in outer groove -arrow B-. The inner groove -arrow A- must remain visible („identification groove“ for correct boot assembly). –  Refer to table → Anchor and pack approx. 70% of indicated quantity of grease inside joint body.

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

–  Slide on constant velocity joint as far as circlip. –  Align circlip so that opening faces upwards -arrows-.

–  Screw old drive shaft bolt into joint body as shown. –  Use plastic hammer to drive joint onto drive shaft until circlip engages. –  Pack remaining quantity of grease into boot side of joint body. –  Push boot onto joint body. –  Vent air from boot. –  Make sure boot is properly positioned on joint body. –  Boot must rest in groove and on contour of joint body. –  Tighten hose clips on outer joint → Fig..

Removing inner sliding constant velocity joint –  Clamp drive shaft in vice using protective jaw covers. –  Fold back rubber boot. –  Use drift -A- to force sliding constant velocity joint off drive shaft. The drift must be applied exactly on the spider of the sliding constant velocity joint. Installing inner sliding constant velocity joint –  Knock joint onto shaft with plastic hammer until circlip engages.

Use clamp tensioner -V.A.G 1682- to fit and tighten stainless steel hose clip, as shown in illustration. –  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 5...50 Nm adjustment range (e.g. torque wrench -V.A.G 1331-). t  Ensure that the thread of spindle -A- is not tight. If necessary lubricate with MOS 2 grease. 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.

Removing protective cap from sliding constant velocity joint 1 -  Three-arm puller, e.g. Kukko 45-2 2 -  Thrust plate -VW 447 H-

Driving protective cap onto sliding constant velocity joint 1 -  Thrust piece -T10243- Drive protective cap onto joint until shoulder -arrow A- engages in groove -arrow B-.