Axle Shafts - Front & Rear Audi A4 B6

DESCRIPTION & OPERATION

These models may be equipped with one of four different front axle shafts. Use following illustrations to determine which axle shaft vehicle is equipped with. (Scheme 1)- (Scheme 4). A4 Avant Quattro and Quattro are equipped with one of two different rear axle shaft. (Scheme 5)or (Scheme 6).

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

LUBRICATION

CV JOINT LUBRICATION (FRONT AXLE)

CV JOINT LUBRICATION (REAR AXLE)

TRIPLE ROLLER JOINT LUBRICATION (AAR 2000)

TRIPLE ROLLER JOINT LUBRICATION (AAR 3300 i)

FRONT AXLE SHAFT

Removal

1. Use pulling hook from in-vehicle tool kit, pull off center cap. Ensure vehicle is standing on its wheels, and loosen hex bolt for outer joint of axle shaft a maximum of 90°.
2. Raise and support vehicle. Remove front wheels. To secure brake disc, thread all wheel bolts into wheel hub. Remove hex bolt for outer joint of axle shaft.
3. Remove nut (1) and hex bolt. (Scheme 7) Lift out both control arms (2). Swing away wheel bearing housing toward side (arrow). Remove axle shaft.

Scheme 7

Scheme 8

Scheme 9

1. Insert axle shaft in wheel bearing housing. Fasten upper links (3 and 4) with bolts (2) and nuts (1) in a position so that links can still be altered (bolts and nuts not fully tightened). (Scheme 8)
2. Adjust height (A) of upper front link to 3.1-3.2" (78-82 mm). (Scheme 9) Adjust height (A) of upper rear link (lower illustration) to 2.7-2.8" (68-72 mm).
3. Press links as far as possible in direction of wheel bearing housing, and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__torque-specifications). Check position of upper link. If necessary, repeat adjustment.
4. Bolt axle shaft to transmission flange. Tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__torque-specifications). Ensure vehicle is not touching ground. Secure axle shaft outer joint.
5. Operate foot brake in vehicle. Tighten front axle shaft-to-wheel hub bolt to Step 1 of torque sequence. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__torque-specifications). Install front wheels. Tighten wheel lug bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__torque-specifications).
6. Lower vehicle until vehicle is standing on wheels. Tighten axle shaft-to-wheel hub bolt to Step 2 of torque sequence. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__torque-specifications).

1. Use pulling hook, from in-vehicle tool kit, pull off center cap. Ensure vehicle is standing on its wheels, and loosen hex bolt for outer joint of axle shaft a maximum of 90°.
2. Raise and support vehicle. Remove front wheels. To secure brake disc, thread all wheel bolts into wheel hub. Remove collared bolt (arrow). (Scheme 10)
3. Insert spring tensioner V.A.G. (1752/1) with spring holder V.A.G. (1752/16) in coil spring. (Scheme 11) If necessary, insert spring holder in individual windings of coil spring, and screw in place with spring tensioner. Tighten spring tensioner as far as stop (arrow). Remove spring.
4. Unscrew socket head bolts (2) and remove heat shield. (Scheme 12) Remove transmission flange bolts (1). Lift trapezoidal link by hand, until axle shaft can be pulled forward, and out of flange shaft and transmission.
5. Press exhaust pipe down slightly (arrow "A"), and push axle shaft inward (arrow "B") until it can be removed from wheel hub. (Scheme 14) Press exhaust pipe down slightly again, and guide axle shaft outward above splash plate. Move axle shaft downward to remove (arrow "A").

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Installation

1. Insert axle shaft from below, and push into wheel hub to stop. Align holes of axle shaft, flange shaft and transmission. Install axle shaft-to-transmission flange bolts (1). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__torque-specifications).
2. Install heat shield and socket head bolts (2). (Scheme 12) Tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__torque-specifications).
3. Insert lug in lower spring (1) in trapezoidal link (2). (Scheme 15) Rotate end of coil spring until contact with spring support stop (arrow "A"). Insert upper spring support (not shown in illustration) in upper end of spring. While aligning spring support in hole of body, loosen spring tension.
4. Install NEW axle shaft collared bolt. Tighten to 148 ft. lbs. (200 N.m). Install wheel. Tighten wheel lug bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__torque-specifications).
5. Lower vehicle until vehicle is standing on wheels. Tighten axle shaft collared bolt an additional 180°.

Scheme 15

Scheme 16

Scheme 17

Scheme 18

1. Remove axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION.
2. Clamp axle shaft in vise with protective jaws. Using a screwdriver, carefully pry off locking cap. (Scheme 16)
3. Remove gasket (arrow). (Scheme 17) Loosen boot clamp. Using a brass or copper drift, drive off cap from CV boot. Remove circlip. (Scheme 18)
4. Using special tools (VW 401, VW411 and VW434), press off inner CV joint. (Scheme 19) Pull CV boot from shaft.
5. Swing ball hub and cage. (Scheme 20) Press joint piece out in direction of arrow. Joint must be disassembled in order to replace grease due to contamination, or if ball tracks must be checked for wear and damage. Press ball bearing out from cage.
6. Flip out ball hub from ball cage via running path of ball bearings (arrows). (Scheme 21)
7. Check joint piece, ball hub, cage and ball bearings for small broken off depressions (pitting build-up) and chafing.
8. Insert ball hub into ball cage via two chamfers. Installation position is at random. Press ball bearings into cage (upper illustration). (Scheme 22)
9. Insert hub with cage and balls upright into joint piece. (Scheme 22) When inserting, ensure that wide gap ("a") at joint piece contacts narrow gap ("b") at hub after swinging in.
10. Swing in ball hub, and swing out hub far enough from cage so that ball bearings have distance of running paths. (Scheme 23) Swing in hub with ball bearings by forcefully pressing onto cage (arrow - lower illustration). Ensure CV joint is properly assembled. CV joint is properly assembled if ball hub can be slid back and forth by hand over whole compensation length.
11. Ensure axle shaft, CV boot, and contact surface of cap are free of grease. Apply sealing compound (454 300 A2), or equivalent, onto clean inner surface of cap for CV boot. Guide sealing compound past inner area of bores (arrow). (Scheme 24)
12. Using special tools (40-204A, VW 401, VW 402 and VW 522), press on joint until joint stops. Press block (40-204A) press block and tensioning area of axle shaft must be free of grease. (Scheme 25)
13. Install NEW circlip. (Scheme 18) Ensure circlip is properly seated. Take care not to damage sealant bead, and press specified amount of grease (G 000 603) into CV boot. See «CV JOINT LUBRICATION (FRONT AXLE)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) table under LUBRICATION.
14. Align NEW boot with NEW cap to bore holes using bolts (arrows). (Scheme 26) Ensure alignment is exact. Using a plastic hammer, drive cap on. Wipe off excess sealant.
15. Press specified amount of grease (G 000 603) through ball tracks into CV joint. See «CV JOINT LUBRICATION (FRONT AXLE)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) table under LUBRICATION. Remove grease contact surface of sealing ring (arrow). (Scheme 17)
16. Remove adhesive foil from seal and bond in CV joint. Align NEW cover to bore holes. Ensure alignment is exact. Using special tools (VW 401, VW 402, VW 412, VW 459/1 and VW459/2), press on cap. (Scheme 27)
17. Position small end of inner CV joint boot between arrows (Scheme 28) Install axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION.

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

1. Remove axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION.
2. Clamp axle shaft in vise with protective jaws. Using a copper or brass mandrel, drive cover off. (Scheme 29)
3. Remove circlip. (Scheme 18) Remove axle shaft grease. Mark installation position of CV joint to axle shaft.
4. Clamp CV joint in vise. (Scheme 30) Have a second mechanic hold axle shaft horizontally to ensure CV joint is not damaged. Using a small flat chisel, bend open edge (arrow) of cap slightly. Using a copper or brass mandrel, strike cap, and drive off axle shaft.
5. Using special tools (VW 402 and VW 409), press CV joint off axle shaft. (Scheme 31) Remove cap and CV boot.
6. Joint must be disassembled in order to replace grease due to contamination, or if ball tracks must be checked for wear and damage. Swing ball hub and cage. (Scheme 20) Press joint piece out in direction of arrow. Press ball bearing out from cage.
7. Flip out ball hub from ball cage via running path of ball bearings (arrows). (Scheme 21)
8. Check joint piece, ball hub, cage and ball bearings for small broken off depressions (pitting build-up) and chafing.
9. Insert ball hub into ball cage via two chamfers. Installation position is at random. Press ball bearings into cage (upper illustration). (Scheme 22)
10. Insert hub with cage and balls upright into joint piece (lower illustration). (Scheme 22) When inserting, ensure that wide gap ("a") at joint piece contacts narrow gap ("b") at hub after swinging in. (Scheme 22)
11. Swing in ball hub, and swing out hub far enough from cage (arrows) so that ball bearings have distance of running paths. (Scheme 23) Swing in hub with ball bearings by forcefully pressing onto cage (arrow - lower illustration). Ensure CV joint is properly assembled. CV joint is properly assembled if ball hub can be slid back and forth by hand over whole compensation length.
12. Ensure axle shaft, CV boot, and contact surface of cap are free of grease. Apply sealing compound (454 300 A2), or equivalent, onto clean inner surface of cap for CV boot. (Scheme 24) Guide sealing compound past inner area of bores (arrow).
13. Place ball hub with chamfer on inside diameter (splines) onto axle shaft. Slide NEW CV boot with cap onto shaft. Press specified amount of grease into CV boot. See «CV JOINT LUBRICATION (FRONT AXLE)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) table under LUBRICATION.
14. Using adhesive tape (arrow), secure CV joint from falling apart. (Scheme 32) Using special tools (40-204A, VW 401, VW 402, VW 412 and VW 516), press on CV joint.
15. Install NEW circlip. Press specified amount of grease through ball bearing tracks, into CV joint. See «CV JOINT LUBRICATION (FRONT AXLE)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) table under LUBRICATION.
16. Align cap with bolts to bolt holes (arrows). (Scheme 26) Ensure alignment is exact. Using a plastic hammer, drive cap on. Wipe off excess sealant.
17. Align cover to bore holes using bolts (arrows). (Scheme 33) Ensure alignment is exact. Using a plastic hammer, drive cover on. Wipe off excess sealant.
18. Install axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION.

Disassembly, Inspection & Reassembly (Outer Joint - 100 & 108 mm Diameters)

1. Remove axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION.
2. Clamp axle shaft in vise with protective jaws. Release boot clamp. Slide CV boot back. Using a hammer and copper or brass drift, drive off inner ring of CV joint. (Scheme 34) Remove joint.
3. Using electric scriber or grindstone, mark position of ball hub to ball cage and housing (arrow) before disassembling. (Scheme 35) Swing ball hub and ball cage. Remove ball bearings in sequence.
4. Turn cage until two rectangular windows (arrow) contact joint body. (Scheme 36) Lift out cage with hub. Swing segment of hub into rectangular window of cage. (Scheme 37) Fold hub out from cage.
5. Insert cage with hub into joint body. Press in opposing ball bearings in sequence. Ensure previous position of ball hub, ball cage and joint body are re-established.
6. Ensure CV boot is free of grease and slide onto shaft. Install NEW circlip. Press specified amount of grease (G 000 603) into CV joint. See «CV JOINT LUBRICATION (FRONT AXLE)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) table under LUBRICATION.
7. Thread old axle shaft bolt into joint piece. (Scheme 38) Using a plastic hammer, drive joint onto shaft until circlip engages. Press specified amount of grease (G 000 603) into CV boot. See «CV JOINT LUBRICATION (FRONT AXLE)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) table under LUBRICATION.
8. Vent CV boot. Tighten NEW boot clamp. Install axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION.

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

1. Remove axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION.
2. Clamp axle shaft in vise with protective jaws. Remove boot clamp, and push CV boot back.
3. Screw special tool (3207 with M16/M14 thread) into joint bolt hole until CV joint is pressed off axle shaft. (Scheme 39) Remove securing ring.
4. Using an electric marker or grindstone, mark position of ball hub in relation to ball cage and housing (arrow). (Scheme 35) Swivel ball hub and ball cage. Remove ball bearings in sequence.
5. Turn cage until two rectangular windows (arrow) make contact with joint body. (Scheme 36) Lift out cage with hub. Swing segment of hub into rectangular window of cage. (Scheme 37) Fold hub out of cage.
6. Insert cage with hub into joint body. Press in opposing ball bearings in sequence. Ensure previous position of ball hub, ball cage and joint body are re-established.
7. Ensure CV boot and seating of boot on axle shaft are free of grease. Slide CV boot onto shaft. Install NEW circlip. Press specified amount of grease into joint piece. See «TRIPLE ROLLER JOINT LUBRICATION (AAR 2000)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) table under LUBRICATION.
8. Thread old axle shaft bolt into joint piece. (Scheme 38) Using plastic hammer, drive joint onto shaft until securing ring engages. Press specified amount of grease into joint, on lining side. See «TRIPLE ROLLER JOINT LUBRICATION (AAR 2000)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) table under LUBRICATION.
9. Vent CV boot briefly to equalize pressure. Tighten boot clamps. Install axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION.

Disassembly, Inspection & Reassembly (Outer Joint - AAR 3300 i)

Note. Manufacturer recommends only replacing outer joint as complete unit. Manufacturer does not provide specific procedures for overhaul of outer CV joint on AAR 3300 i axle shaft. Use following steps and exploded view of axle shaft to aid in inspection and reassembly. (Scheme 4)

Scheme 38

1. Remove axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION.
2. Clamp axle shaft in vise with protective jaws. Release boot clamp. Slide CV boot back. Using a hammer and copper or brass drift, drive off inner ring of CV joint. (Scheme 34) Remove joint.
3. Before installing CV joint, install circlip (1), dished washer (2) and spacer ring (3) on axle shaft. (Scheme 40) Using a plastic hammer, drive joint onto shaft until circlip engages.
4. On vehicles using stainless steel boot clamps, install pliers (VAG 1682). (Scheme 42) Ensure jaws of pliers seat in corners (arrow B) of boot clamp. If thread is tight or dirty, required tightening force for boot clamp will not be achieved, despite correct tightening torque settings. Ensure spindle thread is not tight. If necessary, lubricate with MOS 2 grease. Using a torque wrench with 4-37 ft. lbs. (5-50 N.m) range, tighten boot clamp by turning spindle with torque wrench. Tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__torque-specifications).
5. On other style boot clamps, use pliers (VAG 1275) and tighten boot clamp on CV boot. (Scheme 47) Install axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION.

Scheme 39

CONSTANT VELOCITY JOINT (REAR - INNER)

Note. Replace rear inner CV joint only as complete assembly if defective. No overhaul procedures are provided by manufacturer.

Scheme 40

Scheme 41

1. Remove axle shaft. See «REAR AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) under REMOVAL & INSTALLATION.
2. Drive off inner joint cover. (Scheme 43)
3. Disengage circlip. Using mandrel, knock off CV boot. Using special tools (VW402 and VW 411), press off inner CV joint. (Scheme 44) Support ball hub with plate (VW402) while pressing off inner CV joint.
4. Position ball hub with inside diameter chamfer (splines) on axle shaft. Using special tools (40-204A, VW 401, VW 402, VW 412 and VW 522), press on CV joint as far as possible. (Scheme 25) Engage circlip.
5. Apply sealing compound (454 300 A2), or equivalent, to clean surface of cover or cap. Route around inside of holes (arrow). (Scheme 24) Align cover and cap with bolt holes and knock or press onto joint. Wipe off excess sealant.

Disassembly, Inspection & Reassembly (Inner Joint - 108 mm Diameter)

Note. Replace rear inner CV joint only as complete assembly if defective. No overhaul procedures are provided by manufacturer.

1. Remove axle shaft. See «REAR AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) under REMOVAL & INSTALLATION.
2. Disengage circlip. Using a mandrel, drive off CV boot. Using special tools (T10065/4, VW 401 and VW 409), press off inner CV joint. (Scheme 45)
3. Using special tools (40-204A, VW 401, VW 402, VW 412 and VW 522), press on CV joint as far as it will go. Engage circlip. Position ball hub with inside diameter chamfer (splines) on axle shaft.
4. Apply sealing compound (454 300 A2), or equivalent, to clean surface of cover or cap. Route around inside of holes (arrow). Align cover with bolt holes. (Scheme 24)
5. Install axle shaft. See «REAR AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) under REMOVAL & INSTALLATION.

CONSTANT VELOCITY JOINT (REAR - OUTER)

Note. Replace rear outer CV joint only as complete assembly if defective. No overhaul procedures are provided by manufacturer.

Scheme 42

1. Remove axle shaft. See «REAR AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) under REMOVAL & INSTALLATION.
2. Clamp axle shaft in vise with protective jaws. Release clip and draw CV boot back.
3. Position mandrel "A" precisely at star of CV joint, and knock CV joint off axle shaft. (Scheme 46)
4. Using a plastic hammer, drive CV joint onto axle shaft until circlip engages. Use pliers (VAG 1275) pliers to tighten CV boot clamps. (Scheme 47)

Scheme 43

Scheme 44

Scheme 45

Scheme 46

1. Remove axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION.
2. Clamp axle shaft in vise with protective jaws. Open boot clamp at CV joint, and slide back CV boot. Bend open metal tabs with a flat tip screwdriver, and pry off cover. (Scheme 48)
3. Using a waterproof felt pen, mark installation positions of joint piece, triple-roller connection and axle shaft. (Scheme 49) Remove seal (arrow) from groove. Secure joint piece, and remove axle shaft from vise.
4. Using snap ring pliers, remove circlip from triple roller joint and axle shaft. (Scheme 50) Carefully push CV boot back. If boot is damaged, cut and remove boot from axle shaft.
5. Insert axle shaft into press. (Scheme 51) Secure axle shaft, and press off triple roller joint from axle shaft. Ensure that rollers press off without resistance. Remove triple roller joint with rollers, and set aside on clean surface.
6. Pull joint piece off axle shaft. Pull boot from axle shaft. Clean axle shaft, joint piece and groove for oil seal.
7. Slide CV boot onto axle shaft. Slide joint piece onto shaft. Place tripod connection on shaft according to markings. Chamfer on star faces toward axle shaft. Chamfer is used as an assembly aid. A second mechanic is needed, to slide CV boot to rear. Using special tool (VW 426), fully drive triple roller joint onto shaft. (Scheme 52)
8. Insert securing ring. Ensure proper fit. Press specified amount of grease into triple roller joint. See «TRIPLE ROLLER JOINT LUBRICATION (AAR 2000)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) table under LUBRICATION. Slide joint piece over rollers, and secure.
9. Press specified amount of grease into CV boot. See «TRIPLE ROLLER JOINT LUBRICATION (AAR 2000)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) table under LUBRICATION.
10. Install CV boot. Ensure bead in CV boot engages in joint piece groove. Remove axle shaft from vise, and clamp joint piece. Insert NEW sealing ring (arrow), from repair kit, into groove. (Scheme 49)
11. Install NEW cover on joint piece. Ensure holes on cover and joint piece line up. (Scheme 53) Install clamp.

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

1. Remove axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION. Take care not to damage axle shaft. Clamp axle shaft horizontally in vise with protective jaws.
2. Using a waterproof felt pen, mark position of joint piece to axle shaft. Open tensioning clamps (arrows). (Scheme 54)
3. Slide back CV boot. Insert assembly tool (T40018) behind joint piece. (Scheme 55) Ensure guide pin (1) makes contact with exterior of joint piece. While tightening by hand, turn knurled bolts (2) at joint piece until assembly tool (T40018) makes contact. Ensure joint piece is secured in assembly tool (T40018) without play.
4. Thread special tool (VW771) into special tool (T40018). (Scheme 56) Pull off joint piece horizontally using slide hammer. Leave joint piece in special tool (T40018).
5. Mark installation position of axle shaft (1) and triple roller star (2). (Scheme 57) Using a lint-free cloth, remove grease.
6. Using pliers, remove circlip. (Scheme 58)
7. Using special tools (T10065/1, T10065/4, VW 401, VW 402 and VW 408A), press triple roller star off of axle shaft. (Scheme 51) Remove CV boot. Remove grease from splines of axle shaft. Check roller and track for wear. Clean axle shaft and housing.
8. Slide new CV boot onto shaft. Press on circlip (1) up to center of splines. see scheme 59 Using special tools (T10065/1, T10065/2, VW 411, VW 416B and VW 447H) press circlip (1) into groove on axle shaft. see scheme 60
9. Press triple roller joint onto axle shaft. Chamfer on star faces toward axle shaft. If axle is conical shape, use special tool (T10065/2). see scheme 61 If axle is cylindrical shape, use special tool (T10065/3). see scheme 62
10. On conical and cylindrical shaped axle shafts, use pliers to install securing ring. (Scheme 58)
11. Press specified amount of grease into triple roller joint. See «TRIPLE ROLLER JOINT LUBRICATION (AAR 3300 i)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) table under LUBRICATION. Lightly grease roller body.
12. Using a plastic mallet, drive joint piece over triple roller star. see scheme 63 Press specified amount of grease into CV boot. See «TRIPLE ROLLER JOINT LUBRICATION (AAR 3300 i)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear) table under LUBRICATION. Ensure CV boot makes contact in groove and contour of joint piece.
13. Position joint piece in center position between "min" and "max". see scheme 64 Using a screwdriver, vent CV boot while positioning joint piece (arrow).
14. Mount larger diameter boot clamp on CV boot. Position crimping tab (2) of clamp between mounting flanges (1) of joint piece. see scheme 65
15. Using Pliers (VAG 1275), install and tighten smaller diameter boot clamp on CV boot. (Scheme 47)
16. Install axle shaft. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) under REMOVAL & INSTALLATION.

Scheme 55

Scheme 56

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Scheme 57

Scheme 58

See also:
• TORQUE SPECIFICATIONS
• FRONT AXLE SHAFT
• CV JOINT LUBRICATION (FRONT AXLE)