Question about Volkswagen Passat

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I need some help on puting back together a passenger side front wheel axle for a 1995 volkswagen passat glx. i ordered this axle from a junk yard throght the mail and when it arrived it had all the ball bearings out of it. i tried putting the bearings back in the housing and adding grease and then i installed it on my car. the problem is that the axle will not flex at the transmission end so it can bend down some so it will go into the wheel hub. i suspect that i am not assembling the bearings into the housing correctly. i tried different times to assemble it but everytime the axle would not flex like it is suppose to. can you guide me on exactly how to instll the bearings or send me some kind of schematics to show me what to do. i know the axle is suppose to flex like the other end because it has a rubber boot on it filled with grease. i also bought a driver axle for the this same car and it arrived altogether and the transmission end on that one had the rubber boot and it flexed correctly.

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It is recommended that the balls go back into the grooves each of them came out of. You cannot do this since it was already in pieces when you received it, It is therefore preferable that you rather replace the joint with a new on. (Using 2nd hand or reconditioned joints is not recommended. The initial cost saving will be far outstripped by the shorter joint life) However if you want to reassemble this is how you do it:
Clean all the parts properly.
Look into the the joint housing at the grooves. See that theres no serious damage. (Scoring etc). If the damage is on the left side of each groove then the joint came out of the RH side of a vehicle. If you now install it on the LH side of the vehicle you'll get it to last that little bit longer.
Coat the grooves, inner race, bearing cage and balls with new CV grease(Molybdenum disulphide grease).
Insert the inner race into the cage. Line up the grooves of the race with the holes in the cage. Insert both into the housing. Twist the cage by pressing down on one side or lifting the other side with a screwdriver until you have space to insert the ball between the race and the cage through the hole in the race. Do this with each of the balls. Once done force some grease onto the housing with you fingers and re-insert the shaft. Remember to fit the boot first. Move the shaft around to get all the parts properly coated and to be sure youve assembled it correctly.You have to be able to do this by hand or something is wrong.
If it is not possible then one of the balls is jamming in its particular groove. You can disassemble and try to move each of the balls into the next groove. Put some more grease into the boot and slide it into position on the housing (90grams about 2-3 heaped tablespoons). You can use "cable ties" (Those plastic strips - at least 6mm wide - the cops use for cable ties nowadays) to keep the boot in place. One on each end of the boot. If your cable ties are too short they can be joined together end to end.

Posted on Aug 04, 2010

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