Dismantling and assembling drive shaft with 100 mm or 108 mm dia. inner sliding constant velocity joint (with cap) — AUDI

🧭 Before you start

Clamp the shaft, drive off the cover and cap, release only the small hose clip, remove the circlip and press the joint off; pull off the boot. On assembly, slide the boot on, lightly grease the splines, drive the joint home onto support sleeve VW 522 and fit a new circlip. Pack half the grease from the boot side, seal and fit the cap, pack the rest through the ball races, then seal and fit the cover. Position the boot and tighten the clips with V.A.G 1682 and pliers 3340.

Fits: Audi A5 (8T, 2007–2016), Audi A5 Cabriolet (8F), Audi A4 B8 (8K, 2007–2015)

• Special tools named: torque wrench

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• Always fit a new circlip and check it is fully seated before going further.
• Sealant bead must be continuous, 2 - 3 mm, and routed around the inside of the bolt holes.
• Degrease the contact faces first and wipe off squeezed-out sealant immediately.
• Split the supplied grease: half from the boot side, the remainder through the ball races.
• Keep V.A.G 1682 straight and its jaws on the clip lugs; position the large clip fastener between two holes.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Clamp drive shaft in vice using protective jaw covers.
2. Drive off cover with a copper or brass drift.
3. Drive off cap with a copper or brass drift.
4. Unfasten and detach only the "“small”" hose clip.
5. Remove circlip.

6. Press inner sliding constant velocity joint off drive shaft using tools shown in illustration.
7. Pull boot off drive shaft.
8. Push boot with "“small”" hose clip onto drive shaft.
9. Grease splines (A) on drive shaft lightly with grease used in joint before fitting joint body onto drive shaft.
10. Clamp drive shaft in vice using protective jaw covers.
11. Carefully fit joint onto drive shaft and drive home onto stop with a hammer, making use of the support sleeveVW 522.
12. Fit a new circlip.
13. Check that circlip is properly seated.
14. Before fitting boot, pack half the drive shaft grease provided into joint from boot side of joint.
15. Degrease contact surface for cover.
16. Apply sealant (hatched area) to clean surface on inside of cap on CV joint boot.
17. Apply a continuous sealant bead of ∅ 2 - 3 mm.
18. Route sealant bead around inside of holes (arrow).
19. Use sealantElectronic parts catalogue.
20. Align cap and bolts (arrows) with bolt holes.
21. Drive on cover using a plastic hammer.
22. Remove surplus sealant immediately as it is pressed out.
23. Pack remainder of drive shaft grease into constant velocity joint through ball races.
24. Degrease contact surface for cover and for constant velocity joint.
25. Degrease contact surface for cover and for constant velocity joint.
26. Apply sealant -hatched area- to clean inner surface of cover.
27. Apply a continuous sealant bead of ∅ 2 - 3 mm.
28. Route sealant bead around inside of holes (arrow).
29. Use sealantElectronic parts catalogue.
30. Align cover and bolts (arrows) with bolt holes.
31. Drive on cover using a plastic hammer.
32. Remove surplus sealant immediately as it is pressed out.
33. Push joint boot onto drive shaft.
34. Position boot between (arrows).
35. Make sure boot is properly positioned on drive shaft.
36. Tighten hose clips on inner joint. [Note: When installing the large hose clip, position the fastener between two holes.]
37. Apply clamp tensionerV.A.G 1682 as shown. Ensure jaws of tool make contact with lugs (arrows B) on hose clip.
38. Tighten clip by turning spindle with torque wrench (C) (take care to keep tool straight).
39. Engage hose clip by hand at first lug.
40. Use pliers3340 to fasten hose clip.

🎬 Related video tutorial

Independent AUTODOC tutorial for the same job, filmed on a different model (A4 B5 Saloon) — the technique carries over, the fasteners and figures on this page are the ones for your car.

How to change cv joint on AUDI A4 B5 Saloon

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