Audi Workshop Service and Repair Manuals

Use is made at the front axle of the Audi A4 of a new plastic boot for the 88 mm outer joint (wheel end).

The difference is that this is a harder material than rubber.

Stainless steel hose clamps are required for fitting the boot on account of the higher pre-tensioning force involved.

Rubber boots are tensioned using pliers V.A.G 1275.

Instructions for Fig. 1 apply only to stainless steel clamps.

→ Fig.1    Tensioning clamp at outer joint

• ‒ Apply pliers V.A.G 1682 as shown. Make sure jaws of pliers make contact with corners (arrows B) of hose clamp.
• ‒ Tension hose clamp by turning spindle with torque wrench (take care not to tilt pliers).

• ◆ Tightening torque: 20 Nm
• ◆ Use torque wrench with 5...50 Nm adjustment range (e.g. V.A.G 1331).
• ◆ Make sure thread of spindle on pliers moves freely. Lubricate with MOS2 grease if necessary.
• ◆ If stiff, e.g. due to dirt on thread, required clamp tensioning force will not be attained with specified tightening torque.

→ Fig.2    Pressing off outer constant velocity joint

• ‒ Clamp drive shaft with soft jaws in vice.
• ‒ Detach hose clamp and push back bellows.
• ‒ Screw pressure spindle 3207 with M16/ M14 thread into joint pin until constant velocity joint is pressed off drive shaft.

→ Fig.3     Pressing off inner constant velocity joint

Notes:

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

→ Fig.4    Pressing on inner constant velocity joint

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

Note:

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

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

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

→ Fig.6    Venting boot

• Applies only to rubber boots

Boot is often squashed on positioning it on joint housing. This produces a vacuum in the boot, which causes a fold to form whilst driving (arrow). After fitting, boot is therefore to be vented briefly at small diameter to ensure pressure equalisation.