Volkswagen Touareg 2004-06

CV-Joints

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Overhaul



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove both clamps from the outer constant velocity joint boot. Pull the constant velocity joint boot off.
  4.  
  5. Drive the outer constant velocity joint off of the axle using firm blows with a plastic faced hammer. The outer constant velocity joint cannot be rebuilt and must be replaced if necessary.
  6.  
  7. Remove both clamps from the inner constant velocity joint boot. Pull the boot off.
  8.  
  9. Drive off the cover for the inner constant velocity joint. Remove the circlip using circlip pliers.
  10.  
  11. Press the inner constant velocity joint from the axle.
  12.  
  13. Before disassembling the joint, mark the ball hub position in relation to ball cage and housing.
  14.  
  15. Swivel the ball hub and ball cage. Remove the balls one after another.
  16.  
  17. Lift out the cage together with the hub.
  18.  
  19. Pivot the segment of the hub into an opening in the cage. Tilt the hub out of the cage.

    Click image to see an enlarged view

    Fig. Drive the cover off of the inner joint



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    Fig. Press the inner joint from the shaft as shown



    Click image to see an enlarged view

    Fig. Pivot the segment into an opening, then tilt hub out of the cage

  20.  
  21. Check the stub axle, hub, cage and balls for small indentations or pitting and signs of seizure. Excessive backlash in the joint will be noticed as a knock, in such cases the joint must be replaced. Polished areas and ball track marks are normal; it is not necessary to replace the joint.
  22.  

To install:

  1. Press half of the total amount of grease into the joint body. Total per joint is 1.4 oz. (60 grams).
  2.  
  3. Install the cage with the hub in the joint housing.
  4.  
  5. When installing, make sure that the large chamfer on the inner diameter of the ball hub and the large inner diameter of ball cage face toward the drive axle.
  6.  
  7. Press in the balls one after another from opposite sides until the original position of the hub, cage and joint housing is be restored.
  8.  
  9. Pack the remaining grease into a new joint boot and install the boot.
  10.  
  11. Install a new cover onto the inner constant velocity joint.
  12.  
  13. Press the inner constant velocity joint onto the axle.
  14.  
  15. Install a new circlip onto the axle using circlip pliers.
  16.  
  17. Install boot clamp tool VAG 1682 or equivalent as shown in illustration. Make sure that the jaws of the tension clamp seat in the corners of the clip.
    NOTE
    Make sure the threads of the clamp are not tight and dirty. If necessary lubricate with grease.

  18.  
  19. Tighten the hose clamp to 18 ft. lbs. (25 Nm). Do not bend the tensioning clamp.

    Click image to see an enlarged view

    Fig. Pressing the inner joint onto the shaft



    Click image to see an enlarged view

    Fig. Use tool VAG 1682 or similar to install the boot clamps

  20.  

 
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