Drive Axle With Triple-Rotor Joint, Servicing

Drive axle with triple-rotor joint, servicing





Grease quantity and type

Note:
Pack the outer constant velocity joints with the following greases:

^ 88 mm joint diameter: G 000 603
^ 98 mm joint diameter: G 000 633

CAUTION:
Part numbers are listed here for reference only. Always check with your Parts department for the latest information.





1 - Drive axle with triple-rotor joint

^ Replacement part supplied with boot and filled with grease

2 - Clamp

^ Always replace

3 - Boot for innertriple-rotor joint

^ Check for splits and abrasions
^ Only 32 mm diameter shafts have replaceable inner boots
^ To replace, drive off outer constant velocity joint
^ When slipping onto profiled shaft, apply small quantity of grease to bead on profiled shaft and use VAG1474/5 wedge (part of VAG 1474) to carefully position boot

4 - Clamps

^ Always replace

5 - Boot for outerconstant velocity joint

^ Check for splits and abrasions
^ Before tightening clamp, briefly lift end of boot to equalize pressure (ventilate)
^ As of chassis no. 8DTA 279 794, new boots were introduced for 88 mm outer joint (wheel end)

6 - Clamp

^ Always replace

7 - Spring washer
8 - Spacer washer (plastic)
9 - Circlip

^ Always replace
^ Install into circular groove on axle shaft before installing joint
^ Not visible with joint installed

10 - Outer constant velocity joint

^ Outer diameter 88 or 98 mm, depending on engine/transmission combination
^ Replace as complete part only
^ Installing: use plastic hammer to drive onto axle shaft until circlip engages

Clamps used on rubber joint boots are tightened using VAG 1275 pliers

Instructions in Fig. 1 are only for stainless steel clamps





Fig. 1 Tightening clamp on outer CV joint

- Position VAG 1682 pliers as shown in illustration. Make sure jaws of pliers seat in grooves of clamp (arrows -B-).
- Using torque wrench, turn spindle -A- and tighten clamp.

^ Do not cant pliers
^ Tightening torque: 20 Nm (15 ft lb)

Note:
^ Use a torque wrench with a range of 5-50 Nm (approx. 4-40 ft lb) (e.g. VAG 1331).
^ Make sure spindle -A- turns freely. If necessary lubricate the spindle threads with MOS2 grease.
^ If the spindle does not turn freely (e.g. spindle is dirty), the clamping force required on the clamp will not be achieved even though the correct tightening torque is indicated.





Fig. 2 Pressing off outer constant velocity joint

- Clamp drive axle in vise using protective jaw covers.
- Remove large clamp and slide back boot.
- Thread special tool into end of constant velocity joint until joint is pressed off of axle shaft.





Fig. 3 Ventilating joint boot

Only for rubber joint boot
The joint boot is often pressed in while being installed on the body of the joint. This creates a vacuum inside the boot which draws it inward with a fold (arrow) while driving. Therefore after installing, lift the boot at the small diameter end to equalize pressure.





Fig. 4 Positioning boot over bead of profiled shaft





Fig. 5 Installation positions of spacer washer and spring washer (outer CV joint end)

1 - Spring washer
2 - Spacer washer (plastic)