Inner CV joint, installing Audi A4 B7

Inner CV joint, installing

1. Apply sealant D 454 300 A2 - hatched surface - to clean surface on inner side of protective boot cover or cap, and. Sealant bead: unbroken, 2 to 3 mm dia., skirt area around inner holes - arrow -.

Protective boot and cap contact surfaces must be free of grease!

1. Slide new protective boot with cap onto drive axle.
2. Pack 85 g joint grease into boot.

1. Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.

Scheme 166

1. Secure CV joint from coming apart, e.g. with adhesive tape - arrow -.
2. Press off CV joint.

Note. Position ball hub with chamfer on inner diameter (splines) on drive axle.

Use special tool shown in illustration.

Press block 40-204 A and clamping surfaces on drive axle must be free of grease.

1. Install circlip
2. Press 35 g joint grease into joint through ball races.

1. Using bolts - arrows - , align protective boot and cap with screw holes.

It must be aligned exactly because it cannot be aligned after driving on.

1. Drive off protective boot with cap using plastic hammer.
2. Clear away leaking sealant immediately.

Scheme 167

1. Align new cover with bolts - arrows - to screw holes.

It must be aligned exactly because it cannot be aligned after driving on.

1. Drive cover on with a plastic hammer.
2. Clear away leaking sealing immediately.

Outer CV joint, removing

1. Drive axle, clamping in vise

Use protective vise covers for this.

1. Open clamps.
2. Slide back protective boot

1. Strike a copper or brass drift on CV joint inner race with a hammer.
2. Remove joint

Outer CV joint, installing

1. Slide joint protective boot onto drive axle.
2. Insert new circlip

Circlip (snap ring) must be replaced

1. Pack 80 g joint grease in inside of joint.

1. Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
2. Screw old drive axle bolt into joint as shown in illustration.

1. Drive joint onto drive axle with plastic hammer until circlip engages.
2. Apply 40 g joint grease in boot side of joint.
3. Bleed protective joint boot.
4. Close clamp.

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.

Disassembling

Scheme 168

1. Before disassembling mark ball hub position in relation to the ball cage and housing with an electric scriber or oil stone. (see - arrow -)
2. Swivel ball hub and ball cage.
3. Remove balls one after another.

Scheme 169

1. Turn cage until two cage windows - arrow - rest on joint body.
2. Lift out cage together with hub.

Scheme 170

1. Swing a hub segment in a cage window.
2. Tilt hub out of cage.

Checking

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.

Assembling

1. Install cage with hub in joint housing.

Note. Cage must be installed laterally correct.

1. Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body must be re-established.
2. Pack grease into joint body, grease quantity and type «Grease quantity and type»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

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

Disassembling

Note. Ball hub and joint are paired and should be identified before removal. Do not interchange cage allocation.

1. Swing ball hub and ball cage and pull out of joint in direction of - arrow -.
2. Press balls out of cage.

1. Flip out ball hub from ball cage via running path of ball - arrows -.

Checking

1. Check joint housing, ball hub, ball cage and balls for indentations (pitting) and signs of seizure.

Note. Excessive backlash in the joint will cause knocking or jolts under load change. In such cases the joint must be replaced. Flattening and running marks of balls are no reason to replace joint.

Assembling

1. Insert ball hub into ball cage via two chamfers. The hub can be installed in any position. Press balls into cage.
2. Insert hub with cage and balls at right angle to joint.

Scheme 171

Note. When inserting make sure that the wide space - a - on joint housing is aligned with the narrow space - b - on the hub after swiveling in.

1. Install ball hub, whereby the hub must be swiveled out of the cage - arrows - far enough to allow the balls to fit into the ball tracks.

1. Press cage firmly - arrow - until hub swings fully in position.

Constant velocity joint, checking for function

Constant velocity joint is properly assembled, if ball hub can be slid back and forth by hand over whole compensation length.

When installing waxed components, contact surfaces must be cleaned. Contact surfaces must be free of wax and grease.

Torque specifications for unoiled bolts and nuts are given.

Welding or straightening operations are not permitted on load-bearing or wheel-controlling components.

Always avoid the following actions with coil springs: Hammer stroke, welding beads, applying color identification later.

Do not perform any welding or grinding (separating work) in coil spring or suspension strut area! Cover coil spring or suspension struts if necessary.

Vehicles without drive axle must not be moved, otherwise wheel bearing will be damaged. If vehicle must be moved, observe the following

1. Install an outer joint in place of drive axle.
2. Tighten outer joint to 115 Nm (bolt M14) or 200 Nm (bolt M16).

Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position --> Wheel bearing, lifting to curb weight position

If the vehicle must still be aligned, every bolt and nut that must be loosened for adjustment is only tightened to torque specification. After measurement/adjustment is complete, tighten bolt and nuts to prescribed additional torque angle.