Required tools and materials:
* New inner CV joint
* Ball joint wrench (usually 17mm)
* 22mm wrench
* Hex key set
* Flat head screwdriver
* Long nose pliers
* Puller for CV joints (recommended)
* Grease for CV joints
Instructions for replacing the inner CV joint on a Passat B6 with automatic transmission:
1. Installing the car on a lift or jacks
* Place the vehicle on a lift or raise the front end using jacks.
* Ensure the vehicle is firmly supported and safe.
2. Wheel removal
* Remove the wheel from the problematic side.
3. Disconnecting the steering rod
* Using a hex wrench, loosen the tie rod clamp bolt.
*Grip the tie rod and turn it until it comes out of the ball joint.
4. Disconnecting the ball joint
*Grip the ball joint lever and turn it down.
* Hit the ball joint arm with a hammer or sledgehammer to dislodge it from the steering knuckle.
5. Disconnecting the drive
* Loosen the drive-to-transmission bolts using a 22mm wrench.
* Remove the drive from the gearbox.
6. Dismantling the CV joint
* Using a CV joint puller, remove the CV joint from the drive.
* Slide the CV joint from the axle shaft.
* Remove the O-ring.
7. Installation of a new CV joint
* Clean the axle shaft from dirt and old grease.
* Apply CV joint grease to the new CV joint and axle shaft.
* Place the new CV joint onto the axle shaft.
* Attach the O-ring to the axle shaft.
8. Drive installation
* Insert the drive into the gearbox.
* Tighten the drive mounting bolts.
9. Installation of the ball joint
* Insert the ball joint into the steering knuckle.
* Hit the ball joint arm with a hammer or sledgehammer to force it into place.
10. Steering rod connection
* Insert the tie rod into the ball joint.
* Tighten the clamp bolt.
11. Wheel installation
* Reinstall the wheel.
12. Lowering the car
* Lower the vehicle from the lift or jacks.
Adviсe:
*Tighten all bolts and nuts to the required torque as specified in the owner’s manual.
* It is recommended to replace both CV joints at the same time, even if only one is faulty.
* Make sure O-rings are installed correctly to prevent lubricant leakage.
*If you don’t have a CV joint puller, you can try to remove the CV joint by hand using a large screwdriver and hammer. However, it can be more complicated.