front outer boot rubber

[bigalan000]

I have to replace the front outer cv rubber on my a4 2.5tdi , anyone got any tips on doing this please
Cheers
Big al

[towcestervag]

undo 14/17mm allen key on cv joint end
r/i wheel
pull back abs sensor slightly
remove top suspension/ball joint top bolt(if its not seized) otherwise remove one of the bottom arms
then you should be able to get driveshaft out of the way
use old cv bolt 14/17mm to push old joint off keep it straight
change boot but make sure you put spacers back and tap joint back on

[spartacus 68]

I've had to do this recently on the same car. I made the mistake of fitting a cheap rubber boot from a local motor factors, and ended up having to redo the job a matter of months later as it had split again.

Loosen drive-shaft bolt with the vehicle on the ground. On the original hub bolt - it's a 17mm allen key. I had to buy this, as it's not a regular tool in my tool-box. The replacement hub bolt with an [GKN] CV boot kit will probably be a hex-bolt. It's 27mm in size.

With the hub bolt loosened (it will be on tight - so use an extension bar with 1/2'' drive). Raise vehicle and chock rear wheels. Undo the plastic shroud that the drive shaft goes through. It's held in place with one torx screw.

You should be able to see the inner-drive shaft. Now this is simply my advice - but it's easier to remove the entire driveshaft rather than trying to extract the outer end from from the hub bearing or removing the lower balljoint.

Undo the inner drive-shaft splined bolts. (You'll need a long-shaft splined socket set). If the car is in gear and the opposite wheel is on the ground, then you'll have the necessary resistance to apply pressure. Once the bolts are removed, turn the wheel to hard-lock and you will be able to extract the driveshaft. Clean the bearing surface but be careful not to damage the ABS sensor. I applied a slight smear of lithium grease on the surface of the wheel bearing before refitting. Avoid any grease going near the ABS sensor.

With the drive-shaft removed, cut off the old boot and undo the tie straps. Knock off the CV joint off with a rubber mallet - using sharp blows. Don't use a metal lump hammer as you could damage the joint.

Clean off the worst of the old grease from the CV joint, if necessary - wire brush the outer ABS sensor ring.

Add the new rubber boot and secure the smaller end using the metal tie strap. Next add the plastic cup washer (small end towards the engine) with the metal washer next to the larger side. Add the new CV grease to the CV joint and work in. Normally it comes with two sachets. Use both. You'll definately need latex gloves - it goes everywhere.

The new CV boot kit will have a replacement metal circlip to use on the driveshaft end. Replace this, then add the remainder of the CV grease to the inside of the boot. Now place the CV joint on the splined shaft. A quick knock with a rubber mallet and it will engage. Clean off any excess grease on the grooved ring on the outer surface of the CV joint where the rubber boot will sit. Manouvre the rubber lip of the boot into this groove. If you're happy that the joint feels right (full 360 degree movement), then tie off the outer strap. Job done.

Replacement is as reverse for putting the driveshaft back on. Tighten the driveshaft bolt with vehicle still raised. Ideally it should be torqued to the correct specification while raised - however this may not be possible.