Triple roller joint AAR 2600 i or 3300 i, assembling

WARNING: This page does not describe the selected car, but rather 17 other vehicles, including the 2009 Audi S4, 2009 Audi A4, 2008 Audi S4, 2008 Audi RS 4, and 2008 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Assembly

Slide new protective boot onto drive axle.

Fig 1: Pressing On Circlip To Center Of Splines

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press on circlip - 1 - to center of splines

Fig 2: Assembling Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Use special tool shown in illustration.

Depending on drive axle version, T10065/3 must be used instead of assembly device T10065/2.

Triple roller star, pressing onto drive axle

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

Fig 3: Identifying Joint/Triple Roller Star Splines

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
Install triple roller star onto shaft as per markings and drive in to stop.

Fig 4: Pressing Triple Roller Star Onto Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

This illustration only applies to conical drive axle - arrow - !

Use special tool shown in illustration.

Special tool T10065/2 must not come in contact with roller body

Fig 5: Pressing Triple Roller Star Axle Shaft With Cylindrical Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

This illustration only applies to cylindrical drive axle - arrow - !

Use special tool shown in illustration.

Special tool T10065/3 must not come in contact with roller body

Press triple roller joint onto drive axle
Circlip must engage audibly, triple roller star must lie against circlip with no gap.

Fig 6: Removing/Installing Circlip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install circlip.

1 - Pliers (commercially available)

Press 70 grams of joint grease, from repair kit, into reverse side of triple roller joint.
Lightly lubricate roller body

Make sure roller body does not tilt!

Fig 7: Pressing Joint Over Triple Roller Start With Plastic Hammer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press joint over triple roller start with plastic hammer

Drive axle AAR 3300 i assembly device T40018 is shown in illustration.

Press remaining quantity of grease in protective boot.
Ensure correct seating of boot on joint.
Boot must fit in groove and on joint contour

Fig 8: Triple Roller Joint Positioned Approximately In The Middle Of The Sliding Part

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position joint in center position. See min - max position

NOTE:

While positioning joint in center position, it is necessary to bleed protective boot, e.g. with a screwdriver. - Arrow -

Fig 9: Identifying Clamping Sleeve Connecting Tube & Flanges

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install clamp.

NOTE:

For a better alignment of multi-point socket head bolts when installing drive axle, clamping sleeve connecting tube - 2 - must be between joint connecting flanges - 1 -.

Fig 10: Locating Clamp With Hose Clamp Pliers V.A.G 1275

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tension small clamp using hose clamp pliers V.A.G 1275.