Drive Axle With Triple Roller Joint AAR 2600I, Disassembly And Assembly

Special tools and workshop equipment required

Thrust plate VW 401
Thrust plate VW 402
Punch VW 408 A
Punch VW 411
Sleeve VW 416 B
Thrust pad VW 447 H
Assembly tool T10065

Disassembling

Fig 1: Identifying Removal Of Circlip Using Pliers

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-- Open clamp at shaft and slide back CV boot.

-- Pull off joint piece from drive axle.

-- Remove securing ring.

1 - VW 161 A

-- Insert drive axle in vise.

-- Press triple roller star off drive axle.

Fig 2: Identifying Triple Roller Star Pressed Off From Driveshaft

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-- Pull off CV boot from shaft.

-- Clean shaft, joint and groove for oil seal.

Assembling

-- Slide small clamp for joint protective boot onto shaft.

-- Slide CV boot onto shaft.

-- Slide joint piece onto shaft.

Triple Roller Star, Conical Drive Axle, Installing

The chamfer on star faces toward shaft, this is used as an assembly aid.

-- Before installing CV joint or triple roller star, splines -A- must be lightly coated with grease used in joint.

Fig 3: Identifying Joint/Triple Roller Star Splines

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-- Connect triple roller star on shaft and press on up to stop.

Fig 4: Identifying Installation Of Triple Roller Star Onto Shaft And Press Onto Stop

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-- Make sure that pressure does not increase above 3.0 t!

-- If necessary coat drive axle splines and triple roller star with polycarbamide grease G 052 142 A2.

-- Insert securing ring, be sure to fit properly.

-- Slide joint piece over rollers and secure.

-- Press 70 g drive axle grease from repair kit into triple roller joint.

-- Press 70 g drive axle grease from repair kit into protective joint boot.

-- Install CV boot.

-- Install clamp.

Outer Constant Velocity Joint, Checking

Fig 5: Identifying Joint Body Marking

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It is necessary to disassemble the joint whenever replacing the grease or if the ball surfaces show wear or damage.

Removing

-- Before disassembling mark ball hub position in relation to the ball cage and housing with an electric scriber or oil stone -arrow-.

-- Tilt ball hub and ball cage and remove balls one after another.

-- Turn cage until two cage windows -arrow- rest on joint body.

Fig 6: Ball Cage Windows Level With Joint Body

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-- Lift out cage with hub.

-- Swing a hub segment in a cage window.

Fig 7: Identifying Segment Of Hub Swung Into One Of Cage Windows

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-- Fold hub out from cage.

NOTE:

6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small depressions (pitting build-up) and chafing.

Excessive circumferential backlash in joint makes itself noticed via tip-in shock, in such cases joint should be replaced.

Flattening and running marks of balls are no reason to replace joint.

Installing

Installation is the reverse of removal, with special attention to the following:

-- Press quantity of grease specified in table into joint body.

90mm diameter outer joint, grease quantities, refer to FILLING JOINTS WITH GREASE .
98 mm diameter outer joint, grease quantities, refer to FILLING JOINTS WITH GREASE .

-- Insert cage with hub into joint body.

NOTE:

Cage must be installed laterally correct.

-- Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body must be established again.

-- Install new circlip in shaft.

-- Distribute remaining grease in the joint boot.