Audi Workshop Service and Repair Manuals

Servicing inner constant velocity joint

Removing inner constant velocity joint –  Clamp drive shaft in vice. Use jaw protectors. –  Drive off cover with a copper or brass drift.

–  Remove circlip. –  Remove drive shaft grease and mark installation position of constant velocity joint relative to drive shaft.

–  Clamp constant velocity joint with drive shaft in vice, as shown in illustration. –  A second person must hold the drive shaft horizontal to prevent the constant velocity joint from being damaged. –  Open out rim - arrow - of cap slightly using a small chisel. –  Drive off cap with a copper or brass drift.

–  Press constant velocity joint off drive shaft. –  Take off CV joint boot with cap.

Installing inner constant velocity joint –  Apply sealant D 454 300 A2 on clean inner surface of cover → Item and cap on CV joint boot → Item (hatched area). Route continuous bead of sealant (2 ... 3 mm Ø) around inside of holes -arrow-. Boot and contact surface of cap must be free of grease. –  Push new boot with cap onto drive shaft. –  Pack 85 g of drive shaft grease into boot.

–  Grease splines -A- on drive shaft lightly with grease used in joint before fitting joint or triple roller spider onto drive shaft.

–  Use adhesive tape or similar -arrow- to keep components of constant velocity joint together. –  Press on constant velocity joint.   Note Chamfer on internal diameter of ball hub (splines) must face drive shaft. Use the special tools shown in the illustration. Special tool 40-204 A and the clamping surface on drive shaft must be free from grease. –  Fit circlip. –  Press 35 g of drive shaft grease through the ball raceways into the joint.

–  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.

–  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.