SEAT Workshop Service and Repair Manuals

Servicing inner constant velocity joint Removing inner constant velocity joint –  Clamp the drive shaft in the vice Always use protective jaws in the vice when clamping!

–  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 -cross-hatched area- to clean surface on inside of cover or cap on joint protection sleeve → Item and → Item. Sealant bead: continuous, Ø 2 ... Apply 3 mm to inner hole circumference -arrow-. The drive shaft, boot and the contact surface of the cap must be free of grease! –  Hang a new boot with cap on the drive shaft. –  Fill in 85 gm drive grease in the bellows.

–  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 special tools as shown in the figure. The tensor 40-204A and clamping surface of the drive shaft must be free of 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 accurate, since realignment is not possible after fitting. –  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 accurate, since realignment is not possible after fitting. –  Drive on cover using a plastic hammer. –  Remove surplus sealant immediately as it is pressed out.