Drive Axle, Disassembling And Assembling

Special Tools And Workshop Equipment Required 

• Press Plate VW 401
• Press Plate VW 402
• Press Piece - Rod VW 408A
• Press Piece - Rod VW 411
• Press Piece - 37mm VW 416B
• Press Piece - Multiple Use VW 447H
• Torque Wrench 1331 5-50 Nm VAG 1331
• Torque Wrench 1332 40-200 Nm VAG 1332
• Clamping Pliers VAG 1682A
• Tripod Joint Tool T10065
• Slide Hammer Set VW 771
• Triple Roller Assembly Tool T40018 for triple roller joint AAR 3300 i

Triple Roller Joint AAR 3300 i, Disassembling 

Fig 1: Identifying Clamps & Protective Boot

Courtesy of AUDI OF AMERICA, LLC

-- 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 water-proof felt pen is well-suited for marking.

-- Open clamps -arrows-.

-- Slide back protective boot.

Allocate the Assembly/Removal Tool for Removing the Joint.

Fig 2: Dimension A

Courtesy of AUDI OF AMERICA, LLC

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

• Dimension -A- approximately 76 mm = drive axle with triple roller joint AAR 3300 i, use Triple Roller Assembly Tool T40018

-- Guide in the Triple Roller Assembly Tool T40018 for the triple roller joint AAR 3300 i behind the joint.

Fig 3: Guide Pin & Knurled Thumb Screw

Courtesy of AUDI OF AMERICA, LLC

• Guide pins -1- must contact joint.

-- Move the Triple Roller Assembly Tool T40018 up against the joint by turning knurled screws -2-.

-- Install the Slide Hammer Set VW771 in the Triple Roller Assembly Tool T40018.

Fig 4: Slide Hammer VW 771 & Assembly/Removal Tool T40018

Courtesy of AUDI OF AMERICA, LLC

-- Pull joint out horizontally with impact tool.

• Leave the joint in the Triple Roller Assembly Tool T40018.

-- Mark installation position of the parts -1 and 2- with lines.

Fig 5: Drive Axle, Triple Roller Star & Mark

Courtesy of AUDI OF AMERICA, LLC

If they are not marked and are not installed in their previously installed positions, noises may occur later during driving operation.

A water-proof felt pen is well-suited for marking.

1 -

Drive axle 

2 -

Triple roller star 

-- Remove grease with lint-free cloth.

-- Remove the circlip.

Fig 6: Removing/Installing Circlip

Courtesy of AUDI OF AMERICA, LLC

1 -

Pliers (commercially available) 

Press Triple Roller Star Off of Drive Axle 

Fig 7: Identifying Tool Set Up/Assembly

Courtesy of AUDI OF AMERICA, LLC

-- Use special tool shown in illustration.

1. Assembly Tool T10065/1
2. Triple Roller Assembly Tool T10065/5 - must touch the triple roller star base
3. Press Plate VW 401
4. Press Piece - Rod VW 408A
5. Press Plate VW 402

• The Triple Roller Assembly Tool T10065/5 must not touch the rollers; move the rollers to the side if necessary.

-- Pressing triple roller star off of drive axle.

-- 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 3300 i, Assembling 

Fig 8: Circlip (Snap Ring) & Positioning Protective Joint Boot

Courtesy of AUDI OF AMERICA, LLC

-- Slide on the small clamp with the CV boot and position the CV boot on the drive axle

-- Position protective joint boot between -arrows-.

Tripod Roller Star, Pressing Onto Drive Axle 

Fig 9: Identifying Joint/Triple Roller Star Splines

Courtesy of AUDI OF AMERICA, LLC

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

-- Place triple roller star on shaft according to marking and drive on until impact.

Use the Triple Roller Assembly Tool T10065/6 and make sure it attaches to the bead at the bottom -arrow- in the drive axle.

Fig 10: Identifying Tool Set Up/Assembly

Courtesy of AUDI OF AMERICA, LLC

-- Use special tool shown in illustration.

1. Assembly Tool T10065/1
2. Triple Roller Assembly Tool T10065/6 - must attach to the bead at the bottom of the drive axle -arrow-.
3. Press Plate VW 401
4. Press Piece - 37 mm VW 416B
5. Press Piece - Multiple Use VW 447H
6. Press Piece - Rod VW 411
7. Press Plate VW 402

• The Triple Roller Assembly Tool T10065/6 must not touch the roller; move the rollers to the side if necessary.

-- Install circlip.

Fig 11: Removing/Installing Circlip

Courtesy of AUDI OF AMERICA, LLC

-- Circlip must engage audibly, triple roller star must lie against circlip with no gap.

1 -

Pliers (commercially available) 

-- Press 70 grams of joint grease, from repair kit, into the reverse side of the triple roller joint.

-- Lightly grease the roller body.

-- Press the joint over the triple roller star using a plastic hammer. Make sure roller body does not tilt!

Fig 12: Pressing Joint Over Triple Roller Star Using Plastic Hammer

Courtesy of AUDI OF AMERICA, LLC

-- 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.

-- 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 13: Identifying Clamping Sleeve Connecting Tube & Joint Connecting Flanges

Courtesy of AUDI OF AMERICA, LLC

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