Special tools and workshop equipment required
Removing the outer CV joint
- Clamp the drive axle with protective jaws in a vise clamp.
- Fold back boot.
- Align the Puller - Driveshaft -T10382- so that the flat side of the Puller - Driveshaft - Removing Plate -T10382/1- faces the Puller - Driveshaft - Spindles -T10382/2-.
- Attach the Puller - Driveshaft -T10382- to the Slide Hammer Set -VW771-.
- Remove the CV joint from the drive axle using the Puller - Driveshaft -T10382- and Slide Hammer Set -VW771-.
1 - Puller - Driveshaft - Removing Plate -T10382/1-
2 - Puller - Driveshaft - Spindles -T10382/2-
Installing the outer CV joint
- Install the new circlips.
- Slide new CV boot onto drive axle if necessary.
- Use a plastic hammer to install it on the shaft until the locking ring locks secure.
Disassembling
- Open clamping sleeve on inner joint and slide protective boot back from adapter.
- Remove the joint from the drive axle.
- Remove the circlip.
1 - Pliers (commercially available)
- Insert drive axle into the press.
- Press the triple roller star off the drive shaft.
- Pull off CV boot from shaft.
- Clean shaft, joint and groove for oil seal.
Assembling
- Slide small clamp for joint protective boot onto shaft.
- Slide CV boot onto shaft.
- Slide joint piece onto shaft.
Triple Roller Star, Conical Drive Shaft, Installing
The chamfer on triple roller star faces toward shaft, this is used as an assembly aid.
- Install the triple roller star all the way onto the shaft.
- Make sure the pressure does not increase above 3.0 t.
- If necessary coat drive axle splines and triple roller star with Lubricating Paste -G 052 142 A2-.
- Insert securing ring, be sure to fit properly.
- Press half of the joint grease from the repair set into the triple roller joint.
- Slide joint piece over rollers and secure.
- Press the remaining half of the drive axle grease from the repair kit into the rear side of the triple roller joint.
- Install CV boot.
Triple Roller Star, Cylinder Drive Shaft, Installing
- Install the triple roller star all the way onto the shaft.
- Make sure the pressure does not increase above 3.0 t.
- If necessary coat drive axle splines and triple roller star with Lubricating Paste -G 052 142 A2-.
- Insert securing ring, be sure to fit properly.
- Press half of the joint grease from the repair set into the triple roller joint.
- Slide joint piece over rollers and secure.
- Press the remaining half of the drive axle grease from the repair kit into the rear side of the triple roller joint.
- Slide the CV boot onto the adapter and ensure the boot engages correctly in the groove on the adapter -arrow-.
- Mount and tension the clamp until a proper seal is guaranteed.
Tightening clamping sleeve on outer joint
- Attach the Clamping Pliers -VAG1682A- as illustrated. When doing this, make sure that edges of clamping pliers are seated in corners -arrows B- of clamp.
- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).
Tensioning Clamp on Small Diameter
Note
Removing the Cap from the Triple Roller Joint
1 - Three arm extractor, for example Puller - Kukko 3 Jaw - 100x100mm -12/1-
2 - Press Piece - Multiple Use -VW447H-
Mounting the Cap onto the Triple Roller Joint
1 - Seal Installer - Bevel Box -T10243-
Mount the cap far enough onto the joint until the ridge -arrow A- fits into the groove -arrow B-.