Volkswagen Cars 2000-05

Overhaul

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The constant velocity joints (CV-joints) can be disassembled for cleaning and inspection but they cannot be repaired. All parts are machined to a matched tolerance and the entire CV-joint must be replaced as a unit. On Golf and Jetta, the CV-joints are different on the left and right sides and cannot be interchanged.

  1. Raise and safely support the vehicle and remove the halfshaft.
  2.  
  3. Pry open and remove the boot clamps with a pair of wire cutters.
  4.  
  5. With the halfshaft securely clamped in a vise, the outer CV-joint can be removed by sharply rapping out on the joint with a plastic hammer. The joint will snap off of the circlip and slide off the axle.
  6.  
  7. To remove the inner joint, remove the circlip from the center and slide the joint off the axle.
  8.  
  9. Both boots can be removed after removing the CV-joint
  10.  

To install:

  1. Always replace both circlips and make sure the CV-joint is clean before installation. Wrap a piece of black electrical tape around the shaft splines and slip the inner clamp and the boot onto the shaft.
  2.  
  3. Remove the tape and install the dished washer with the concave side out so it acts as a spring pushing the CV-joint out. On the outer joint, install the thrust washer and a new circlip.
  4.  
  5. To install the outer joint, place it onto the spline and carefully tap straight in on the end with a plastic hammer. The joint will click into place over the circlip.
  6.  
  7. 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.
  8.  
  9. Pack the CV-joint with special CV-joint grease. DO NOT use any other type of grease.
  10.  
  11. Pack any remaining grease into the boot and install the clamps on the outer boot.
  12.  

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.

CV-Joint & Boot Overhaul



Refer to the procedure for CV-joint overhaul under manual transaxle in this section.



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.

The constant velocity joints (CV-joints) can be disassembled for cleaning and inspection but they cannot be repaired. All parts are machined to a matched tolerance and the entire CV-joint must be replaced as a unit. On Golf,GTI and Jetta, the CV-joints are different on the left and right sides and cannot be interchanged.

  1. Raise and safely support the vehicle and remove the halfshaft.
  2.  
  3. Pry open and remove the boot clamps with a pair of wire cutters.
  4.  
  5. With the halfshaft securely clamped in a vise, the outer CV-joint can be removed by sharply rapping out on the joint with a plastic hammer. The joint will snap off of the circlip and slide off the axle.
  6.  
  7. To remove the inner joint, remove the circlip from the center and slide the joint off the axle.
  8.  
  9. Both boots can be removed after removing the CV-joint
  10.  

To install:

  1. Always replace both circlips and make sure the CV-joint is clean before installation. Wrap a piece of black electrical tape around the shaft splines and slip the inner clamp and the boot onto the shaft.
  2.  
  3. Remove the tape and install the dished washer with the concave side out so it acts as a spring pushing the CV-joint out. On the outer joint, install the thrust washer and a new circlip.
  4.  
  5. To install the outer joint, place it onto the spline and carefully tap straight in on the end with a plastic hammer. The joint will click into place over the circlip.
  6.  
  7. 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.
  8.  
  9. Pack the CV-joint with special CV-joint grease. DO NOT use any other type of grease.
  10.  
  11. Pack any remaining grease into the boot and install the clamps on the outer boot.
  12.  

 
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