VW Passat & Audi A4 1990-2000

Front CV Joint/Boot

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The CV boot allows the CV joint to rotate and pivot, while retaining the lubricant and protecting the CV joint from water and debris.

A torn, damaged or leaking CV boot should be replaced immediately. Loss of lubricant will cause the joint to overheat and damage it. Because these are precision-machined components, they can be quite expensive to replace. The cost of the boot is about 10-20% of the cost of a CV joint.

Typically a failed CV joint makes a clicking noise during acceleration, especially when accelerating from a stop and turning.

REMOVAL AND INSTALLATION
Outer CV Joint/Boot
  1. Remove the halfshaft assembly and place it in a suitable and sturdy vise.
  2.  
  3. Pry open and remove both of the CV boot clamps with a pair of wire cutters. New clamps should be used for reassembly.
  4.  
  5. If the CV boot is to be reused, spray the axle with a light penetrating lubricant and slide the boot down the shaft. Carefully inspect the boot for cracking, tears and weathering and replace as necessary.
  6.  
  7. To remove the outer CV joint, wrap a suitable shop towel around the axle to protect its finish and clamp the halfshaft axle securely in a vise.
  8.  
  9. The outer CV-joint is removed by rapping sharply on the joint with a plastic, aluminum or brass hammer. Pull outward on the joint while rapping on the on the joint to release it and slide it off the axle. The joint will snap off the circlip and slide off the axle. BEFORE removing the circlip make sure to note the installation direction of the dished washer and whether or not any spacers are used.
  10.  

To install:

  1. Always replace the circlip and make sure the CV-joint is clean before installation.
  2.  
  3. If the boot is to be replaced;
  4.  
    1. Remove the circlip, then, if equipped, the spacer, and then the dished washer, noting their installation direction.
    2.  
    3. Remove the boot from the axle.
    4.  
    5. Wrap electrical tape around the end of the shaft's splines, lubricate the shaft by spraying a light coating of lubricant on it, and slide the inner clamp and boot onto the shaft.
    6.  

  5. Remove the tape and install the dished washer with the concave side out. If equipped, install the thrust washer/spacer and a new circlip.
  6.  
  7. To install the outer joint, first thread the old axle fastener onto the end of the shaft. If the fastener is a nut thread it on until it is almost fully installed. If the fastener is a threaded hex bolt, thread it into the axle until is bottoms.
  8.  
  9. Align the splines of the CV joint with the axle and place it onto the splines. Carefully tap straight on the fastener with a plastic, brass or aluminum hammer. The joint will click into place over the circlip.
  10.  


NOTE
Always use designated CV-joint grease. Do NOT use any other type of grease.

  1. Using a 1 1 / 2 inch (38mm) wide paint or gasket scraper ideally made of plastic, pack the CV joint with the proper quantity of CV joint grease, such as Part No. G 000 603.
  2.  
  3. Once the CV joint is properly packed, fill the area to be surrounded by the CV boot with the proper quantity of CV joint grease, such as Part No. G 000 603.
  4.  

Outer CV joint Grease Quantity

1990-97 Passat



Outer CV joint: 100g (3.5 oz)
 
(50g (1.8 oz) in CV joint, (1.8 oz) 50g in boot)
 

A4, 1998-00 Passat



88mm (3.5 inches) Outer CV joint: 90g (3.2 oz)
 
(40g (1.4 oz) in CV joint, 50g (1.8 oz) in boot)
 
98mm (3.9 inches) Outer CV joint: 120g (4.2 oz)
 
(80g (2.8 oz) in CV joint, 40g (1.4 oz) in boot)
 

  1. To install the inner joint, slide it onto the spline and push in enough to allow the circlip to fit into the groove in the axle shaft.
  2.  
  3. Slide the CV boot into position and install the clamps. If the clamp has small holes that are installed over small tabs, a small, suitable flat blade screwdriver can be placed through the hole with the tip on the lock tab, then carefully pry the clamp until the hole seats on the tab.
  4.  
  5. Use a pair of suitable CV joint crimping pliers to crimp and secure the clamps.
  6.  
  7. Install the halfshaft.
  8.  



Click image to see an enlarged view

Fig. Use an 1 1 / 2 inch (38mm) wide spatula or scraper to pack the CV joint with an approved grease



Click image to see an enlarged view

Fig. The outer CV joint is driven off the shaft using a soft-faced hammer, such as plastic, aluminum or brass



Click image to see an enlarged view

Fig. An exploded view of the components of the halfshaft. Note, both inner and outer CV joints are the ball-type construction



Click image to see an enlarged view

Fig. An exploded view of the components of a halfshaft using a ball-type outer CV joint and a triple-rotor inner CV joint



Click image to see an enlarged view

Fig. On 1990-97 Passat models use 100g (3.5 oz) for the outer, and 110g (3.9 oz) for the inner CV joint. Apply the grease evenly, half the amount for the joint, the other half distributed in the boot



Click image to see an enlarged view

Fig. A detailed view of the triple-rotor CV joint. The cover and O-ring can be discarded if a kit supplied sealing ring is used. The sealing ring is not used in production



Click image to see an enlarged view

Fig. The ear band clamp is assembled by placing the holes in the clamp onto the tabs, and then securing the clamp using a suitable crimping tool



Click image to see an enlarged view

Fig. The outer CV joint is held onto the axle with circlip



Click image to see an enlarged view

Fig. Make sure to install the dished washer properly

Inner CV Joint/Boot

The inner CV joints on 1990-97 Passat models are similar to the outer CV joint ball-type construction, using an inner yoke that is coupled to an outer yoke by a series of six hardened balls that are surrounded by a race.

The Audi A4 and 1998-00 Passat models use two types of inner CV joints, either the ball-type CV joints as found on earlier Passat models or the triple-rotor CV joint.

The triple-rotor CV joint is easy to identify by its mounting flange, which is almost star-like in its appearance as opposed to the cylindrical shape of the ball-type CV joint.

  1. Remove the halfshaft assembly and place it in a suitable and sturdy vise.
  2.  
  3. Pry open and remove of the CV boot clamp(s) with a pair of wire cutters. New clamps should be used for reassembly.
  4.  
  5. If the CV boot is to be reused, spray the axle with a light penetrating lubricant and slide the boot down the shaft. Carefully inspect the boot for cracking, tears and weathering and replace as necessary.
  6.  
  7. To remove the ball-type CV joint and/or boot;
  8.  
    1. Wrap a suitable shop towel around the axle to protect its finish and clamp the halfshaft axle securely in a vise.
    2.  
    3. Matchmark the CV joint to the axle with a chisel or waterproof felt-tipped marker.
    4.  
    5. Using a pair of suitable snap-ring pliers, remove the circlip on the end of the shaft.
    6.  
    7. If the CV boot is attached to a metal housing without a clamp, use a chisel or a suitable drift to release the housing from the CV joint.
    8.  
    9. Lubricate the axle and slide the boot down the axle.
    10.  
    11. Support the CV joint with a suitable press plate and press the axle out.
    12.  
    13. If removing the CV boot, if installed, remove the dished washer noting its installation direction for reassembly, then remove the boot.
    14.  

  9. To remove the triple-rotor type CV joint and/or boot;
  10.  
    1. Wrap a suitable shop towel around the inner CV joint housing to protect its finish and clamp it securely in a vise.
    2.  
    3. Using a chisel or suitable prytool carefully pry the cover off. A sealing ring is available in a repair kit to replace the cover and allow installation without reusing the cover.
    4.  
    5. Matchmark the axle, the yoke, and the outer housing with a chisel or waterproof felt-tipped marker.
    6.  
    7. Remove the O-ring, and if not reinstalling the cover replace it during installation with the sealing ring.
    8.  
    9. Matchmark the three rollers with the yoke and remove noting their installation direction for reassembly.
    10.  
    11. Using a pair of suitable snap-ring pliers, remove the circlip on the end of the shaft.
    12.  
    13. Lubricate the axle and slide the boot down the axle.
    14.  
    15. Support the yoke with a suitable press plate or loosely in the jaws of a suitable vise and press the axle out.
    16.  
    17. If removing or replacing the CV boot, remove the boot.
    18.  


To install:

  1. Clean the components and removing the old grease.
  2.  
  3. If the CV boot was removed, wrap the end of the axle with electrical tape, the spray the axle shaft with a light lubricant and slide on the small CV boot clamp and then the CV boot, then if removed install the dished washer.
  4.  
  5. Wrap a suitable shop towel around the axle to protect its finish and clamp the halfshaft axle securely in a vise.
  6.  
  7. Align the matchmarks and install the CV joint or on triple-rotor type joints, install the large CV boot clamp, the housing and then the yoke. On halfshafts using a yoke, make sure the chamfered side of the yoke is installed toward the axle.
  8.  
  9. Install a new circlip on the end of the axle.
  10.  


NOTE
Always use designated CV-joint grease. Do NOT use any other type of grease.

  1. Using a 1 1 / 2 inch (38mm) wide paint or gasket scraper ideally made of plastic, pack the CV joint with the proper quantity of CV joint grease, such as Part No. G 000 603.
  2.  
  3. Once the CV joint is properly packed, fill the area to be surrounded by the CV boot with the proper quantity of CV joint grease, such as Part No. G 000 603.
  4.  

Inner CV joint Grease Quantity

1990-97 Passat



Inner CV joint: 110g (3.9 oz)
 
(55g (1.95 oz) in CV joint, (1.95 oz) 55g in boot)
 

A4, 1998-00 Passat



100mm (3.9 inches) Inner CV joint: 80g (2.8 oz)
 
(30g (1.1 oz) in CV joint, 50g (1.8 oz) in boot)
 
108mm (4.3 inches) Inner CV joint: 120g (4.2 oz)
 
(35g (1.2 oz) in CV joint, 85g (3.0 oz) in boot)
 

  1. Slide the CV boot into position and install the clamps. If the clamp has small holes that are installed over small tabs, a small, suitable flat blade screwdriver can be placed through the hole with the tip on the lock tab, then carefully pry the clamp until the hole seats on the tab.
  2.  
  3. Use a pair of suitable CV joint crimping pliers to crimp and secure the clamps.
  4.  
  5. Install the halfshaft.
  6.  

 
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