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  1. #1
    Veteran Member Four Rings fly300kts's Avatar
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    A4 B7 - Inner CV Boot Replacement

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    Hi,

    I finally found time to tackle this issue: Inner Boot Shaft replacement.
    The outer side is pretty straightforward and I will talk about it a bit later but I could not find anything about the inner boot, and itís the trickier one. So here we go:

    Time: 2 Hrs
    Difficulty: 4

    Tools:
    Generic
    Triple Square 10mm
    Allen socket 17mm

    So here is your problem


    Remove the rim center cap and parking brake ON. This will allow you to remove the big Allen screw.



    Then, jack up the car and remove the wheel.
    Remove the cross bolt securing the upper arms as well as the direction control arm.



    You can use a small chisel to expand the arm


    Slide the assembly on the side and you will be able to disengage the axle outer side.


    Then, using the 10mm triple square, remove the 6 screws engine side and slide out the axle.
    After securing the axle, using a razor blade (or other) cut the remaining on the boot as well as the old clamps. Clean any excess of grease. Not like this outer CV Joint where at this stage, you will be able to remove outside clip and slide out the tripod, for the inner joint, you donít have access to the outer clip. With a hammer, hit the flange where the 6 screws were, until she slides off the tripod and you should end up with something like this:



    Now you have access to the outer clip. Remove it and slide out the tripod



    After a good cleaning of the different components, slide the part in this order:

    Small Clamp
    New Boot
    Inner clip



    Slide the tripod and come in contact to the inner clip. Then install the outer clip


    Slide the boot in his final position and tight the inner clamp.


    Empty the entire tube of grease inside the boot, install the outer clamp and secure.



    Reinstall the axle on the car.

    Flange Torque values:
    M8 bolt: 40 Nm
    M10 bolt: 65 Nm

    For the next step a second person is required.
    1st person gets into vehicle and presses brake pedal.
    2nd person tightens hex bolt for drive axle to initial torque.

    Hex bolt (M14): 115 Nm
    Hex bolt (M16): 200 Nm

    Install wheel and lower vehicle to the ground.
    Turn bolt securing drive axle an additional 180į(1/2)

    Let me know if any question

    Phil
    Last edited by fly300kts; 02-28-2016 at 05:59 AM.

  2. #2
    Veteran Member Three Rings illegitimus's Avatar
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    2006 B7 A4 Quattro Tip S-line
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    Boston, MA

    As always, best DIY! Saved and subscribed. Thanks!

  3. #3
    Veteran Member Four Rings Tusin's Avatar
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    Anchorage, AK

    haha freaking awesome DIY. If it was me I would just replace entire axle. But I am kind of lazy:)

  4. #4
    Veteran Member Four Rings Hyphy's Avatar
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    CT

    i love my CPO :)
    Nick
    I'm not driving fast, I'm flying low.

  5. #5
    Established Member Two Rings FASTONE's Avatar
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    04 I35, 05.5 A4
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    KMC/Erfenbach

    Very nicely done Phil. A must keep for the DYI archives.

  6. #6
    Veteran Member Four Rings Doctor's Avatar
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    A4 B7 20vt Quattro,Golf MKV GT
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    Excellent and really helpful...Thumbs up Phil, as always
    Audi A4 in an RS4 body powered by ToM's Garage
    Mike

  7. #7
    Veteran Member Four Rings B72.0T's Avatar
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    12' Mercedes GLK350 4Matic, 04' GLI
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    Nice write-up as always :)
    B8 S4 6-speed
    GIAC Stage II

  8. #8
    Veteran Member Four Rings Tusin's Avatar
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    Quote Originally Posted by Hyphy View Post
    i love my CPO :)
    As long as you keep it stock (which by your sig, looks like you are). But CPO doesn't matter two-bits once you do ANYTHING to the suspension, in regards to your CV Axel's.

  9. #9

  10. #10
    Senior Member Three Rings
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    Norcal

    Great write up.

    Do you use new bolts on the CV and a new Allen on the hub end? What size is that allen?

    Might also be a great time to change the front bearing, since the shaft is out.
    05.5 A4 Avant, KW v3, Stasis exhaust, JHM SSshifter.

  11. #11
    Veteran Member Four Rings fly300kts's Avatar
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    03 Golf GTI - 03 Golf 2.0l - 04 Golf 2.0L
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    South Florida - Ft Lauderdale

    Same bolts were used
    As noted in the beginning of the DIY = Allen 17 mm
    In reference to the bearings, my dad always told me: if ain't broken, don't touch it

    Phil

  12. #12
    Senior Member Two Rings dynamic's Avatar
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    2004 A4 3.0 Quattro
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    Tempe, AZ - Maple/Ash

    It is also helpful to have some dowel pins and a mallet for removing the bearing set from the spline shaft. Mine was on there pretty good. When getting the arms to fit back on, some c-clamps were helpful as well. And I borrowed the crimping tool from Pep Boys. Thanks for the DIY. Helped a lot today!

  13. #13
    Senior Member Two Rings rs6's Avatar
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    For the lazy, you can just get reman'd axles from Napa for (typically) less than $80 w/ lifetime warranty. They are original Audi axles. Beats spending the time and all that nasty grease.

  14. #14
    Established Member Two Rings Nail Nutter's Avatar
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    2008 A4 2.0TQM
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    PDX

    Hey Phil,

    Axel bolts are commonly stretch bolts. You might want to take a look at those bolts from time to time to make sure they aren't backing off. I replaced an axel on my old VW and wasn't able to buy new axel bolts at the same time. I appropriately torqued the bolts when I reinstalled them, but was surprised to find several had worked themselves loose when I checked on them a year later.

  15. #15
    Veteran Member Four Rings fly300kts's Avatar
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    03 Golf GTI - 03 Golf 2.0l - 04 Golf 2.0L
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    South Florida - Ft Lauderdale

    ^^
    Not mentioned in the DIY but I replaced them

    Phil

  16. #16
    Established Member Two Rings Nail Nutter's Avatar
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    2008 A4 2.0TQM
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    Glad to hear it. Great DIY!

  17. #17
    Veteran Member Three Rings audidrver's Avatar
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    CA

    Hey Fly where can i pick up those specific clamps and clampers at? Also will those work for the smaller ones, : for power steering lines.
    ooooO..................Ooooo
    ...............oooo

    .........o.............o

  18. #18
    Veteran Member Three Rings pape's Avatar
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    just did this to my b6 without removing the axel from the car (pasengers side inner boot)

  19. #19
    Veteran Member Four Rings fly300kts's Avatar
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    03 Golf GTI - 03 Golf 2.0l - 04 Golf 2.0L
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    Quote Originally Posted by audidrver View Post
    Hey Fly where can i pick up those specific clamps and clampers at? Also will those work for the smaller ones, : for power steering lines.
    Yes they should work and the clamps came with the repair kit

    Phil

  20. #20
    Veteran Member Four Rings derrek's Avatar
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    arizona

    Anyone have problems removing the 6 triple square bolts? Got 3 out but the other 3 wont budge with a 1/2 inch impact gun. I've already snapped one triple square socket.

  21. #21
    Veteran Member Four Rings fly300kts's Avatar
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    Get a good bit Like Snap-on and try with an impact wrench

    Phil

  22. #22
    Veteran Member Four Rings derrek's Avatar
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    Quote Originally Posted by fly300kts View Post
    Get a good bit Like Snap-on and try with an impact wrench

    Phil
    It was a Matco bit, lifetime replacements are awesome btw. Ended up heating it with a torch for 30 sec, then it came right out.

  23. #23
    Veteran Member Four Rings shiro1745's Avatar
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    South Jersey

    Thanks for this nice DIY Phil
    - Chip

    K0R-GT -- S3 injectors -- Maestro tune -- IE Drop-in rods

    "It took 4 bad crankshaft seals and lots of cursing to build my avatar"

  24. #24
    Established Member Two Rings
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    '03 A4 Quat, '75 Bronco
    Location
    Austin, TX

    Thanks for the helpful info, I figured I'd throw my two cents in on my experience with removing the driveshaft. It could save a bit of work plus the need for a realignment.

    I found I didn't have to unhook any of the upper links (photos/comments in the DIY above as upper arms, direction control arm) from the wheel bearing housing. If it turned the wheel hard over I found I could wiggle the driveshaft out without much trouble at all. I was doing the right front, so I turned the wheel all the way to the right. Crawled under the car. Used the play in the inner CV joint to "shrink" the arm. And was then able to pull it out going back and down (i.e. towards the left rear of the car.)

    The Audi internal ELSA docs say to remove the two upper arms but not to remove either of the bolts on the direction control arm (for alignment reasons) IF there is not enough clearance to remove the driveshaft; so maybe that trick won't work for everyone.

    Here's the text of the process, bolts 1 and 2 are for the two uppers arms, 3 and 4 are for the direction control arm:


    Removing drive shaft
    – Remove wheel trim; on light-alloy wheels, pull off trim cap (use puller in vehicle tool kit).
    – Slacken off bolt for outer joint of drive shaft by max. 90į (vehicle must be standing on its wheels to avoid accident risk).
    – Remove wheel.
    – Screw in and hand-tighten all 5 wheel bolts again.
    – Remove hexagon bolt for outer joint of drive shaft.
    – Unbolt drive shaft from flange shaft on gearbox.
    Perform the following step if there is not enough clearance to take out the drive shaft.

    – Remove nut -1-, take out hexagon bolt and pull out both upper links -2- upwards.
    Do not attempt to enlarge slots in wheel bearing housing using a chisel or similar.
    NoteDo not loosen bolts -3- and -4- as this would change the front axle alignment.
    – Swing wheel bearing housing out to the side.
    – Take out drive shaft.

    Installing drive shaft
    – Insert drive shaft in wheel bearing housing.
    – Fit two upper links, install new bolt and tighten new nut → Item. Press links as far as possible towards wheel bearing housing when tightening.
    – Bolt drive shaft to flange shaft on gearbox → Item.
    – Secure outer joint of drive shaft.
    NoteThe wheels must not be in contact with the ground when initially tightening the bolt securing the outer drive shaft joint; otherwise the wheel bearing can be damaged.
    A second mechanic is required for the next operation.
    – 1st mechanic gets into vehicle and presses brake pedal.
    – 2nd mechanic tightens hexagon bolt for drive shaft to initial torque.
    Hexagon bolt (M14): 115 Nm
    Hexagon bolt (M16): 200 Nm
    – Fit wheel and lower vehicle onto the ground.
    – Turn bolt securing drive shaft a further +180į. (Only turn the bolt through this additional angle when the vehicle is standing on wheels: accident risk).

  25. #25
    Established Member Two Rings
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    Sacramento

    Hey guys. I delved into this over the weekend and ended up finding out I ordered the wrong part (8E0-498-203). I have looked at ECS tuning the the kit the have i guess is a updated part with "C" added after the PN.

    I am having an issue with the bigger end of the boot being completely round where as the one that came off is formed to fit snug.

    Any help is much appreciated!

  26. #26
    Established Member Two Rings multiphrenic's Avatar
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    May 15 2010
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    toronto, ontario

    Just found out my outer boot on the passenger side is torn..thinking of doing the repair this weekend. Do I need to remove the axle or can I just loosen it and move it to one side?
    2007 A4 2.0TQ - Debadged | APR Stage I | LED Interior | RNS-E 2010 Retrofit

  27. #27
    Veteran Member Four Rings fly300kts's Avatar
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    Nope,
    you need to remove the complete axle

    phil

  28. #28
    Senior Member Two Rings xX_Audi_S4_xX's Avatar
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    Just ordered my pass side inner boot last night from JHM. Doing it myself for 50 bucks sure does beat paying 500 bucks at the dealer.

  29. #29
    Senior Member Two Rings xX_Audi_S4_xX's Avatar
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    Whats the Torque spec for the 17mm Allen head bolt?

  30. #30
    Veteran Member Four Rings mcpcartier's Avatar
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    08 xB, 13 Ex, 16 Civic EX
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    SoCal

    Did this today and tried to pull the driveshaft without disconnecting the control arms and tie rod but didn't have any luck. As soon as I popped those off there was more than enough clearance to slide the axle out.
    2007 2.0T Q 6MT, S-Line, Ti Package, BB
    Revo Stage 2 | JHM Stage 1 Clutch | K&N Drop in | APR HPFP | 034 HFC | AWE Catback | 034 SD Tranny & Motor Mounts | Neuspeed Snub | H&R Sport Springs | Bilsteins | Moog ACA | B5 Perches (removed) | RS4 RSB | ABT Drilled n Slotted Rotors | Redstuff Front & Akebono Rear | Podi Stepper Boost Gauge | Recaro's | H&R Spacers 15f/20r | Clear Corners w/Blackout | Smoked Frt Markers | Cupra R Lip | 20% Tint

  31. #31
    Veteran Member Four Rings mcpcartier's Avatar
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    Quote Originally Posted by xX_Audi_S4_xX View Post
    Whats the Torque spec for the 17mm Allen head bolt?
    I tried using the 200NM plus 180 noted earlier in this thread, but there was no way I could physically accomplish that with the tools I have. I did 200NM and got about 45 degrees added before calling it a day. My breaker bar was ready to give out.
    2007 2.0T Q 6MT, S-Line, Ti Package, BB
    Revo Stage 2 | JHM Stage 1 Clutch | K&N Drop in | APR HPFP | 034 HFC | AWE Catback | 034 SD Tranny & Motor Mounts | Neuspeed Snub | H&R Sport Springs | Bilsteins | Moog ACA | B5 Perches (removed) | RS4 RSB | ABT Drilled n Slotted Rotors | Redstuff Front & Akebono Rear | Podi Stepper Boost Gauge | Recaro's | H&R Spacers 15f/20r | Clear Corners w/Blackout | Smoked Frt Markers | Cupra R Lip | 20% Tint

  32. #32
    Veteran Member Four Rings eMacPaul's Avatar
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    Does anyone know the torque for the six triple-square bolts?
    2007 A4 2.0T CVT Cabriolet S-Line Phantom Black
    APR, K&N air filter, Podi boost gauge, chrome-stripped grille, RS4 RSB
    Smoked side reflectors & markers, smartTOP, Eibach Pro-Kit, 12F/15R spacers, ER SMIC
    Xenon match DRLs, LED fogs, city w/ fogs, S4 mirrors, red LED interior, CC, 034 HFC + Magnaflow 14829

  33. #33
    Established Member Two Rings
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    Quote Originally Posted by mcpcartier View Post
    I tried using the 200NM plus 180 noted earlier in this thread, but there was no way I could physically accomplish that with the tools I have. I did 200NM and got about 45 degrees added before calling it a day. My breaker bar was ready to give out.
    This is really too late to reply with help, but the only way I was able to get them out was by heating them up, and backing them out. It was really simple once they were warmed up.

    Hope this helps any others searching for info!

  34. #34
    Established Member Two Rings
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    San Diego/Bay Area CA

    So by hitting off the inner tripod its not going to ruin it? It seems that it was machined to keep it from coming off..

  35. #35
    Veteran Member Four Rings fly300kts's Avatar
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    03 Golf GTI - 03 Golf 2.0l - 04 Golf 2.0L
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    Quote Originally Posted by cali kid View Post
    So by hitting off the inner tripod its not going to ruin it? It seems that it was machined to keep it from coming off..
    No, all safe

    Phil

  36. #36
    Registered Member Four Rings waiapasi2006's Avatar
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    Suzuki Alstare RIP
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    SFL

    Bring back this thread. I just received these and will bee using this DIY to tackle it. Any pointers anyone. I've read some was able to install it by turning the steering wheel to one end while working from the opposite. Will this be the same as the 3.2L FWD?
    Also, I only received on of those big hex bolts, but two axles. Is that correct?


    Waiapasi2006

  37. #37
    Senior Member Two Rings MarilynB6's Avatar
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    2005 S4, 2008 DTM S4, 1993 Ford Bronco
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    Newmarket, NH

    You need a hex bolt per axle. It's what holds the hub to the axle shaft.

  38. #38
    Registered Member Four Rings waiapasi2006's Avatar
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    Quote Originally Posted by MarilynB6 View Post
    You need a hex bolt per axle. It's what holds the hub to the axle shaft.
    I know that. My second one will be shipped out for me to finally get this done next weekend.
    Waiapasi2006

  39. #39
    Established Member Two Rings Newman378's Avatar
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    Quote Originally Posted by waiapasi2006 View Post
    I know that. My second one will be shipped out for me to finally get this done next weekend.
    Then why did you ask? lol

  40. #40
    Veteran Member Four Rings viceprp's Avatar
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    On the B5/B6 you don't need to touch the control arms to remove the axel. Just turn the steering wheel 3/4 and pull out. I'm sure it's the same for the B7. Just be careful not to damage the ABS sensor.
    '00 1.8TQM - Lugtronic GTcougaR
    '02 1.8TQ - Daily sold
    '05 Colorado Z71 Crew Cab
    STEVE

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