Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 830

Removing the Inner CV Joint
Assembling

Installed Location of the Plate Spring on Inner Joint
1 - Plate Spring

Pressing on Inner CV Joint

Note

Chamfer on inner diameter of ball hub (splines) must face the

contact shoulder on the drive axle.

Tightening Clamping Sleeve on Outer Joint
– Position Clamping Pliers - VAG1682A- as shown in illustration.

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).

Note

♦

The hard material of the joint boot (compared to rubber) makes

it necessary to use a stainless steel hose clamp. It is only pos‐

sible to tighten the hose clamp with Clamping Pliers -

VAG1682A- .

♦

Tightening specification: 25 Nm.

♦

Use torque wrench -C- with adjustment range 5 to 50 Nm (for

example Torque Wrench 5-50Nm - VAG1331- ).

♦

Be sure thread of spindle -A- of clamp tool moves freely.

Grease with MOS 2 grease if necessary.

♦

If the thread is tight, for example, dirty, the required tensioning

force for the hose clamp will not be achieved in spite of correct

torque specification settings.

Tensioning Clamp on Small Diameter

6.6.2

Drive Axle, Disassembling and Assem‐

bling, CV Joint VL107

Special tools and workshop equipment required
♦ Press Plate - VW401-
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW408A-
♦ CV Joint Press Sleeve - VW522-
♦ Press Block - 40-204A-
♦ Clamping Pliers - VAG1682A-
♦ Puller - Driveshaft - T10382/1-
♦ Spindles - T10382/2-
♦ Puller - Driveshaft - T10382-
♦ Slide Hammer Set - VW771-
♦ Torque Wrench 1331 5-50Nm - VAG1331-

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Bolt - Outer CV Joint to Drive Axle
♦ Clamps - CV Boot
Removing the Outer CV Joint
– Secure the drive axle with protective covers in a vise clamp.
– Fold back boot.
– Align the Puller - Driveshaft - T10382- so that the flat side of

the Puller - Driveshaft - T10382/1- faces the 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.

Drive Off Cover for Inner Joint
– Remove the circlip.
– Remove both clamps, and push the CV boot toward outer joint.
– Drive off the CV boot with a drift.

Removing the Inner CV Joint
Assembling

Pressing On Inner CV Joint
– Press on joint until stop.
– Install the circlip.

– Coat the cover sealing surface with -D 454 300 A2- .
– Apply a continuous sealant bead with a 2 to 3 mm diameter in

the area of the inner holes -arrow- on the clean surface of the

cover.

– Align new cover with bolts -arrows- to bolt holes.
It must be aligned exactly because it cannot be aligned after driv‐

ing on.
– Drive cover on with a plastic hammer.
– Wipe away any sealant leaking out.