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 - 37 mm:VW416B 
• Press Piece - Multiple Use:VW447H 

Special Tools And Workshop Equipment Required 

• Hose Clip Pliers:VAG1275A 
• Torque Wrench 1331 5-50 Nm :VAG1331 
• Torque Wrench 1332 40-200 Nm :VAG1332 
• Clamping Pliers:VAG1682A 
• Tripod Joint Tool:T10065 
• Hose Clip Pliers:VAG1275A 
• Torque Wrench 1331 5-50 Nm :VAG1331 
• Torque Wrench 1332 40-200 Nm :VAG1332 
• Clamping Pliers:VAG1682A 
• Tripod Joint Tool:T10065 
• Slide Hammer Set:VW771 
• Triple Roller Assembly Tool:T40018  for triple roller joint AAR 3300 i
• or Triple Roller Assembly Tool:T40084  for triple roller joint AAR 2600 i
• Brass or Copper Drift

Triple Roller Joint AAR 2600 i or 3300 i, Disassembling

-- Clamp drive axle horizontally in vise.

-- 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-.

-- Slide Back Protective Boot.

Distinguishing Characteristic of Drive Axle AAR 2600 i to AAR 3300 i

-- Determine dimension -A- as shown in illustration.

• Dimension -A- 74 mm = drive axle AAR 2600 i
• Dimension -A- 77 mm = drive axle AAR 3300 i

-- Guide triple roller joint AAR 3300 i :T40018  or triple roller joint AAR 2600 i :T40084  behind joint.

Guide Pins -1- Must Contact Joint.

-- Move the :T40018  up against the joint by turning knurled screws -2-.

-- Install the :VW771  in the :T40018  or the :T40084  .

Drive Axle AAR 3300 i :T40018  is shown in illustration.

Use :T40084  with drive axle AAR 2600 i.

-- Pull joint out horizontally with impact tool.

Leave The Joint In The :T40018  or the :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.

1. :T10065/1 
2. :T10065/5  - must touch the triple roller star base
3. :VW401 
4. :VW408A 
5. :VW402 

The :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 2600 i or 3300 i, 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 :T10065/6  and make sure it attaches to the bead at the bottom -arrow- in the drive axle.

-- Use special tool shown in illustration.

1. :T10065/1 
2. :T10065/6  - must attach to the bead at the bottom of the drive axle -arrow-.
3. :VW401 
4. :VW416B 
5. :VW447H 
6. :VW411 
7. :VW402 

The :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 3300 i :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.

-- Install clamp.

-- Install the clamps on the triple roller joint. Refer To CLAMP ON TRIPLE ROLLER JOINT AND OUTER JOINT, TENSIONING .