Outer constant velocity (CV) joint, checking Audi A4 B6

Outer constant velocity (CV) joint, checking

In order to replace grease in case of strong soiling, joint must be disassembled or if journal surface of balls must be checked for wear and damage.

Removing

Scheme 172

1. Before disassembling mark ball hub position in relation to ball cage and housing using an electric scriber or oil stone.
2. Swivel ball hub and ball cage.
3. Remove balls one after another.

Scheme 173

1. Turn cage, until two rectangular windows - arrow - contact joint body.
2. Lift out cage together with hub.

Scheme 174

1. Swing segment of hub into rectangular window of cage.
2. Tilt hub out of cage.

6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small indentations (pitting) and signs of seizure. Excessive backlash in the joint will cause knocking or jolts under load change. In such cases joint should be replaced. Flattening and running marks of balls are no reason to replace joint.

Installing

1. Install cage with hub in joint housing.
2. Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body must be re-established.

Scheme 175

Special tools, testers and auxiliary items required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Punch VW 408 A
4. Punch VW 411

1. Sleeve VW 416 B
2. Thrust pad VW 447 H

Scheme 176

Special tools, testers and auxiliary items required

1. Hose clamp pliers V.A.G 1275
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332
4. CV joint boot clamp tool V.A.G 1682

1. Assembly tool T10065

Scheme 177

1. Slide hammer - complete set VW 771

Scheme 178

1. Assembly device T40018 for triple roller joint AAR 3300 i
2. or Assembly device T40084 for triple roller joint AAR 2600 i

Filling triple roller joint shaft with grease

Grease joint again when replacing protective joint boot.

Scheme 179

1 - Clamp

1. Always replace
2. Different clamps possible depending on model
3. Can also be installed with pliers 3340

2 - CV boot for triple roller joint

1. Protective joint boot must fit in groove and on joint contour.

3 - Clamp

1. Always replace

4 - Circlip

1. Only present on certain versions

5 - Spring washer

1. Only present on certain versions
2. Installed location «Location of spacer and spring washer (wheel side)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#suspension-wheels-steering)

6 - Spacer ring (plastic)

1. Only present on certain versions
2. Installed location «Location of spacer and spring washer (wheel side)»(/audi/a4/b6-2000-2006/remont/axle-shafts/#suspension-wheels-steering)

7 - Circlip

1. Always replace
2. Insert before mounting in ring groove (not visible with joint installed)

8 - Outer constant velocity joint

1. Replace only as a unit
2. Pressing off «Driving outer constant velocity joint down»(/audi/a4/b6-2000-2006/remont/axle-shafts/#suspension-wheels-steering)
3. Installing
4. Drive joint onto shaft with a plastic hammer until circlip engages.

1. Greasing --> «Component overview»(/audi/a4/b6-2000-2006/remont/axle-shafts/#suspension-wheels-steering)
2. When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in joint.

9 - Bolt

1. Always replace if removed
2. Loosen «Remove drive axle»(/audi/a4/b6-2000-2006/remont/axle-shafts/#suspension-wheels-steering__remove-drive-axle)
3. Fastening «Install drive axle»(/audi/a4/b6-2000-2006/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle)
4. Torque specification «Install drive axle»(/audi/a4/b6-2000-2006/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle)

10 - Clamp

1. Different versions for protective joint boot in rubber or Hytrel
2. Replace

11 - Outer constant velocity protective joint boot

1. Check for tears and chafing
2. Before clamping hose clamps, raise protective joint boot briefly to balance pressure «Protective joint boot, ventilating»(/audi/a4/b6-2000-2006/remont/axle-shafts/#suspension-wheels-steering)
3. Different version in rubber or Hytrel

12 - Clamp

1. Replace

13 - Axle shaft

1. Different versions

14 - Circlip

15 - Triple roller star

1. Chamfer - arrow - faces splines drive axle splines
2. When installing triple roller star on profile shaft, profile shaft splines must be lightly coated with grease used in joint.

16 - Circlip

1. Replace
2. Insert in shaft groove

17 - Multi-point socket head bolt

18 - Triple roller joint housing

Joint protective boots made from rubber are tightened with hose clamp pliers V.A.G 1275.

Scheme 180

Scheme 181

1. Secure drive axle with protective covers in vise clamp.
2. Remove large clamping sleeve and turn back protective joint boot.
3. Strike a copper or brass drift on CV joint inner race with a hammer

Scheme 182

Only for joint protective boot of rubber

A vacuum can form in joint when installing protective joint boot.

This pressure pulls a fold in while driving, see - arrow -.

Note the following

1. Before clamping, clamping sleeves, balance pressure by raising protective joint boot.

Scheme 183

Items 1 to 3 only present on certain versions.

1 - Circlip

2 - Spring washer

3 - Spacer ring (plastic)

Instructions only apply to stainless steel clamps.

Scheme 184

Tightening hose clamp on outer joint

1. Position CV Joint Boot Clamp Tool VAG 1682 as shown in illustration. Make sure that the jaws of tension clamp seat in corners - arrows B - of hose clip.
2. Tighten hose tie by turning spindle using a torque wrench (do not bend tensioning clamp).

1. Torque specification: 20 Nm
2. Use torque wrench with a range of 5 to 50 Nm (e.g. torque wrench V.A.G 1331).
3. Ensure the spindle thread is not tight. If necessary lubricate with MOS 2 grease.
4. If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.