Drive Axle, Disassembling And Assembling

Special Tools And Workshop Equipment Required 

• Press Plate :VW401 
• Press Plate :VW402 
• Press Piece - Rod :VW408A 
• Press Piece - Rod :VW411 
• Press Piece - 37mm :VW416B 
• Press Piece - Multiple Use :VW447H 
• Torque Wrench 1331 5-50Nm :VAG1331 
• Torque Wrench 1332 40-200Nm :VAG1332 
• Clamping Pliers :VAG1682A 
• Tripod Joint Tool :T10065 
• Slide Hammer Set :VW771 
• Triple Roller Assembly Tool :T40018  for triple roller joint AAR 3300 i

Triple Roller Joint AAR 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.

Allocate The Assembly/Removal Tool For Removing The Joint 

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

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

-- Guide in the :T40018  for the triple roller joint AAR 3300 i behind the 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  .

-- Pull joint out horizontally with impact tool.

• Leave the joint in the :T40018  .

-- 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 the circlip.

1 - Pliers (commercially available)

Press 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.

-- 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 

-- 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 

-- 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 :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.

-- Install circlip.

-- 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!

-- 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.

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