Drive Axle, Disassembling And Assembling
Special tools and workshop equipment required
- Press Plate VW401
- Press Plate VW402
- Press Piece - Rod VW408A
- Press Piece - Multiple Use VW411
- Press Piece - 37mm VW416B
- Press Piece - Multiple Use VW447H
Special tools and workshop equipment required
- Hose Clip Pliers VAG1275A
- Torque Wrench 1331 5-50Nm VAG1331
- Torque Wrench 1332 40-200Nm VAG1332
- Clamping Pliers VAG1682A
- Tripod Joint Tool T10065
- Hose Clip Pliers VAG1275A
- Torque Wrench 1331 5-50Nm VAG1331
- Torque Wrench 1332 40-200Nm VAG1332
- Clamping Pliers VAG1682A
- Tripod Joint Tool T10065
- Slide Hammer Set VW4771
- Triple Roller Assembly Tool T40018 for triple roller joint AAR 3300i
- or Triple Roller Assembly Tool T40084 for triple roller joint AAR 2600i
- Brass or Copper Drift
Triple Roller Joint AAR 2600i or 3300i, Disassembling
-- Clamp drive axle horizontally in vise.
Use vice clamp jaw protectors.
Make sure that drive axle is not damaged.
-- Mark the location of the joint to the drive axle
If they are not marked and are not installed in their previously installed positions, noises may occur later during driving operation.
A waterproof felt pen is well-suited for marking.
-- Open clamps -arrows- in illustration (Fig 1).
-- Slide back protective boot.
Distinguishing Characteristic of Drive Axle AAR 2600i to AAR 3300i
-- Determine dimension -A- as shown in illustration.
- Dimension -A- 74 mm = drive axle AAR 2600i
- Dimension -A- 77 mm = drive axle AAR 3300i
Make sure that correct special tool allocation for each drive axle.
-- Guide triple roller joint AAR 3300i Triple Roller Assembly Tool T40018 or triple roller joint AAR 2600i Triple Roller Assembly Tool T40084 behind joint.
Guide pins -1- must contact joint.
-- Move the Triple Roller Assembly Tool T40018 up against the joint by turning knurled screws -2-.
Joint must be secured without play in Triple Roller Assembly Tool T40018 or Triple Roller Assembly Tool T40084.
Tighten the screws -2- by hand only.
-- Install the Slide Hammer Set VW4771 in the Triple Roller Assembly Tool T40018 or the Triple Roller Assembly Tool T40084.
Drive Axle AAR 3300i Triple Roller Assembly Tool T40018 is shown in illustration.
Use Triple Roller Assembly Tool T40084 with drive axle AAR 2600i.
-- Pull joint out horizontally with impact tool.
Leave the joint in the Triple Roller Assembly Tool T40018 or the Triple Roller Assembly Tool T40084.
-- Mark installation position of the parts -1- and -2- with lines.
If they are not marked and are not installed in their previously installed positions, noises may occur later during driving operation.
A waterproof felt pen is well-suited for marking.
1 -
Drive Axle
2 -
Triple roller star
-- Remove grease with lint-free cloth.
-- Remove securing ring.
1 -
Pliers (commercially available)
-- Pressing triple roller star off of drive axle.
-- Use special tool shown in illustration.
- Assembly Tool T10065/1
- Triple Roller Assembly Tool T10065/5 - must touch the triple roller star base
- Press Plate VW401
- Press Piece - Rod VW408A
- Press Plate VW402
The Triple Roller Assembly Tool T10065/5 must not touch the rollers; move the rollers to the side if necessary.
-- Remove the protective boot.
-- Remove the grease on the shaft splines.
-- Check the roller body and ball cage for wear.
-- Clean drive axle and housing.
Triple Roller Joint AAR 2600i or 3300i, Assembling
-- Slide on the small clamp with the protective boot and position the protective boot on the drive axle according to the version.
Version with Identification Groove:
-- Position CV boot in outer groove -arrow B-.
Inner groove -arrow A- remains visible "identification groove" (for correct installation of CV boot).
Version with Base:
-- Position protective joint boot between -arrows-.
Tripod Roller Star, Pressing onto Drive Axle
The chamfer on the triple roller star faces the drive axle. This is used as an assembly aid.
-- Before installing joint or triple roller star, splines -A- must be lightly coated with grease used in joint.
-- Position the triple roller start on the shaft according to the marking.
Use the Triple Roller Assembly Tool T10065/6 and make sure it attaches to the bead at the bottom -arrow- in the drive axle.
-- Use special tool shown in illustration.
- Assembly Tool T10065/1
- Triple Roller Assembly Tool T10065/6 - must attach to the bead at the bottom of the drive axle -arrow-.
- Press Plate VW401
- Press Piece - 37mm VW416B
- Press Piece - Multiple Use VW447H
- Press Piece - Rod VW411
- Press Plate VW402
The Triple Roller Assembly Tool T10065/6 must not touch the roller; move the rollers to the side if necessary.
-- Press the triple roller joint onto the drive axle.
-- Install circlip.
-- Circlip must engage audibly, triple roller star must lie against circlip with no gap.
1 -
Pliers (commercially available)
-- Press approximately 60% of the joint grease from the repair set into the back of the triple roller joint.
-- Lightly grease the roller body.
Make sure roller body does not tilt!
-- Press the joint over the triple roller star using a plastic hammer.
Drive Axle AAR 3300i Triple Roller Assembly Tool T40018 is shown in illustration.
-- Press remaining quantity of grease in protective boot.
-- Make sure the protective boot is seated on the joint correctly.
-- Protective joint boot must fit in groove and on joint contour.
-- Position joint in center position. See the min - max position.
Vent CV boot -arrow-, for example using a screwdriver, while positioning joint piece in center position.
-- Install clamp.
For a better alignment of multipoint socket head screws when installing drive axle, clamping sleeve connecting tube -2- must be between joint connecting flanges -1-.
-- Install the clamps on the triple roller joint. Refer to CLAMP ON TRIPLE ROLLER JOINT AND OUTER JOINT, TENSIONING .