Volkswagen Tiguan Service and Repair Manual: Drive Axle with CV Joint VL 107 Bolted

Overview - Drive Axle with CV Joint VL 107 Bolted

1. Bolt
   • There are different versions.
   • Allocation. Refer to the Parts Catalog.

WARNING

• There are two types of twelve-point bolts, with and without ribs. Distinguishing characteristics.
• When installing a twelve-point bolt, always check what type of twelve-point bolt is to be used.
• Use the correct tightening specification for the specific bolt.
• The tightening specification for a twelve-point bolt "with" ribs is 70 Nm + 90º. Refer to → Chapter "Twelve-Point Bolt with Ribs, Loosening and Tightening, Drive Axle Threaded Connection" for loosening and tightening specifications.
• The tightening specification for a twelve-point bolt "without" ribs is 200 Nm + 180º. Refer to → Chapter "Twelve-Point Bolt without Ribs, Loosening and Tightening, Drive Axle Threaded Connection" for loosening and tightening specifications.

• Always replace if removed

2. Outer CV joint
   • Replace only as a complete unit.
   • Removing.
   • Installing: Using a plastic hammer, drive onto the shaft as far as the stop
   • Checking.Circlip
3. Circlip
   • Always replace if removed
   • Insert in shaft groove
4. Clamp
   • Always replace if removed
   • Tensioning.
5. CV Boot
   • Check for tears and scuffing
   • Material: Hytrel polyelastomer
6. Clamp
   • Always replace if removed
   • Tensioning.
7. Driveshaft
8. Clamp
   • Always replace if removed
   • Tensioning.
9. CV Boot for CV Joint
   • Material: Hytrel polyelastomer
   • Without vent hole
   • Check for tears and scuffing
   • Drive off CV joint using drift
   • Coat the sealing surface with -D 454 300 A2- before installing it on the CV joint
10. Clamp
    • Always replace if removed
    • Tensioning.
11. Backing Plate
    • Always replace if removed
12. Cap
    • Carefully drive off using a drift
    • Coat the sealing surface with -D 454 300 A2- before installing it on the CV joint
    • Adhesive surface must be free of oil and grease
13. Inner CV Joint
    • Replace only as a complete unit.
    • Removing.
    • Installing.
    • Checking.
14. Circlip
    • Remove and install using Circlip Pliers -VW161A-.
15. Cover
    • Always replace if removed
    • Always replace
    • Removing.
16. Internal Multi-Point Bolt
    • First tighten diagonally to 10 Nm, then tighten diagonally again to the tightening specification
    • 70 Nm
    • M10 x 52
    • After disassembly, always replace bolts

Difference between A Twelve-Point Bolt with Ribs and A Twelve-Point Bolt without Ribs

The contact surfaces -arrow A- and -arrow B- are different on the two-point bolts.

1. Twelve-point bolt with ribs -arrow A-
2. Twelve-point bolt without ribs -arrow B-

Drive Axle with CV Joint VL107, Disassembling and Assembling

Special tools and workshop equipment required

• Press Plate -VW401-
• Press Plate -VW402-
• Press Piece - Rod -VW408A-
• CV Joint Press Sleeve -VW522-
• Press Block -40-204A-
• Clamping Pliers -VAG1682A-
• Torque Wrench 1331 5-50Nm -VAG1331-
• Slide Hammer Set -VW771-
• Puller - Driveshaft -T10382-

Removing the Outer CV Joint

• Clamp the drive axle with protective jaws in a vise clamp.
• Fold back boot.
• Align the Puller - Driveshaft -T10382- so that the flat side of the Puller - Driveshaft - Removing Plate -T10382/1- faces the Puller - Driveshaft - Spindles -T10382/2-.
• Attach the Puller - Driveshaft -T10382- to the Slide Hammer Set -VW771-.
• Remove the CV joint from the drive axle using the Puller - Driveshaft -T10382- and Slide Hammer Set -VW771-.

1. Puller - Driveshaft - Removing Plate -T10382/1-
2. Puller - Driveshaft - Spindles -T10382/2-

Installing the Outer CV Joint

• Install the new circlips.
• Slide the new CV boot onto the drive axle if necessary.
• Use a plastic hammer to install it on the shaft until the locking ring locks secure.

Drive Off Cover for Inner Joint

• Remove the circlip.
• Remove both clamps, and push the CV boot toward outer joint.
• Drive out CV joint boot with a drift.

Inner CV Joint, Removing

Assembling

Pressing On the Inner CV Joint

• Press on joint until stop.
• Install the circlip.

• Coat the cover sealing surface with -D 454 300 A2-.
• Apply unbroken sealant bead with 2 to 3 mm diameter in area of inner holes -arrow- to clean cover surface.

• Align new cover with bolts -arrows- to bolt holes.

It Must be Aligned Exactly Because it Cannot be Aligned after Driving On.

• Drive cover on with a plastic hammer.
• Wipe away any sealant leaking out.

Tightening Clamp On Outer Joint

• Attach the Clamping Pliers -VAG1682- as illustrated. When doing this, make sure that edges of clamping pliers are seated in corners -arrows B- of clamp.
• Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).

Note

• The hard material of the CV boot (compared to rubber) makes it necessary to use a stainless steel hose clamp. It is only possible to tighten the hose clamp with Clamping Pliers -VAG1682A-.
• Tightening specification: 25 Nm.
• Use torque wrench -C- with adjustment range 5...50 Nm (for example Torque Wrench 1331 5-50Nm -VAG1331-).
• Make sure the threads on the spindle -A- on the pliers move easily. Lubricate with MOS 2 grease, if necessary.
• If it does not move freely, for example due to dirt in thread, the required clamp tension will not be achieved at the specified torque.

Tensioning Clamp on Small Diameter

Outer CV Joint, Checking

It is necessary to disassemble the joint whenever replacing the grease or if the ball surfaces show wear or damage.

Removing

• Mark position of ball hub to ball cage and to housing before disassembling, using an electric engraver or grindstone.
• Swivel the ball hub and ball bearing cage.
• Remove the balls one after the other.

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

• Swing segment of hub into rectangular window of cage.
• Fold hub out from cage.

6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small depressions (pitting build-up) and chafing. Excessive circumferential backlash in joint makes itself noticed via tip-in shock, in such cases joint should be replaced. Flattening and running marks of balls are no reason to replace joint.

Installing

• Press in half of the total grease amount (40 grams) into joint body.
• Insert cage with hub into joint body.
• Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body must be established again.
• Install new circlip into the hub.
• Distribute remaining grease in cover.

Inner CV Joint, Checking

Removing

It is necessary to disassemble the joint whenever replacing the grease or if the ball surfaces show wear or damage.

• Swivel the ball hub and ball bearing cage.
• Remove the joint in the direction of the -arrow-.
• Remove the balls from the cage.

Note

Ball hub and joint piece are paired. Do not interchange.

• Flip out ball hub from ball cage via running path of ball -arrows-.
• Check joint piece, ball hub, ball cage and balls for small broken off depressions (pitting build-up) and chafing.

Excessive circumferential backlash in joint makes itself noticed via tip-in shock. Joint must be replaced in such cases. Flattening and running marks of balls are no reason to replace joint.

Installing

• Insert ball hub into ball cage via two chamfers. The installation position is at random. Press balls into cage.

Ball hub has 2 different distances between ball tracks, a larger and a smaller.

• Insert hub with cage and balls upright into joint piece, a smaller space -b- must face toward open side of joint piece when doing this.
• Also note chamfer on inner diameter of ball hub, it must be visible after swiveling in.

• Swing in ball hub; to do so, swing out hub far enough out of cage -arrows- (as depicted in illustration).

• Swing in hub with balls by pressing forcefully onto cage -arrow-.

CV Joint, Checking for Function

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