Drive Axle With Triple Roller Joint AAR 2600I, Servicing, Bolted

WARNING: This page is about a different variant/trim than selected.

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
Tripod Joint Tool: T10065

Removing the Outer CV Joint:

Fig 1: CV Joint Removal

Courtesy of AUDI OF AMERICA, LLC

-- Remove the CV joint from the drive axle by hitting it with a light alloy hammer.

Location of Spacer Ring and Plate Spring:

Fig 2: Identifying Dished Washer And Thrust Washer On Outer Joint

Courtesy of AUDI OF AMERICA, LLC

1 - Plate Spring

2 - Spacer ring (plastic)

Installing the Outer CV Joint

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

Fig 3: Apply Grease

Courtesy of AUDI OF AMERICA, LLC

-- Install old drive shaft bolt in joint as shown in the illustration.

Fig 4: Drive Joint Onto Shaft With Plastic Hammer Until Circlip Engages

Courtesy of AUDI OF AMERICA, LLC

-- Drive joint onto shaft with plastic hammer until circlip engages.

Rubber Protective Joint Boot, Ventilating:

The CV boot is frequently pressed in when placed on the CV joint body. This creates a vacuum in the CV boot, which pulls a fold inward when the car is driven -arrow-.

Fig 5: Identifying Protective Joint Boot, Ventilating

Courtesy of AUDI OF AMERICA, LLC

Therefore, note the following:

-- Before clamping the clamping sleeves, balance pressure by raising CV joint boot.

Tension the CV Joint Boots Stainless Steel Clamps:

Fig 6: Identifying Clamping Pliers VAG 1682A

Courtesy of AUDI OF AMERICA, LLC

-- Position : VAG1682A as shown in illustration. When doing this, make sure that edges of clamping pliers are seated in corners -arrows B- of clamp.

-- Tighten the hose clamp by turning spindle -A- using a torque wrench (do not tilt clamping pliers).

Tightening specification: 20 Nm

NOTE:

Be sure clamp tool spindle thread -A- moves freely. Grease with MoS₂ grease if necessary.

If the thread is tight for example, dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.

Small Clamps for Rubber Protective Joint Boots, Tensioning:

Fig 7: Clamping Using VAG1275

Courtesy of AUDI OF AMERICA, LLC

Triple Roller Joint, Disassembling:

Fig 8: Identifying Removal Of Circlip Using Pliers

Courtesy of AUDI OF AMERICA, LLC

-- Open clamp at shaft and slide back CV boot.

-- Remove the joint from the drive axle.

-- Remove securing ring.

1 - Clamp (commercially available) or : VW161A

-- Insert drive axle in vise.

-- Press triple roller star off drive axle.

Fig 9: Identifying Triple Roller Star Pressed Off From Driveshaft

Courtesy of AUDI OF AMERICA, LLC

-- Pull off CV boot from shaft.

-- Clean shaft, joint and groove for oil seal.

Assembling:

-- Slide small clamp for joint protective boot onto shaft.

-- Slide CV boot onto shaft.

-- Slide joint piece onto shaft.

Triple Roller Star, Conical Drive Shaft, Installing:

The chamfer on triple roller star faces toward shaft, this is used as an assembly aid.

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

Fig 10: Apply Grease

Courtesy of AUDI OF AMERICA, LLC

-- Install the triple roller star all the way onto the shaft.

Fig 11: Identifying Installation Of Triple Roller Star Onto Shaft And Press Onto Stop

Courtesy of AUDI OF AMERICA, LLC

-- Make sure that pressure does not increase above 3.0 t.

-- If necessary coat drive axle splines and triple roller star with Polycarbamide grease : G 052 142 A2 .

-- Insert securing ring, be sure to fit properly.

-- Slide joint piece over rollers and secure.

-- Press 70 g drive shaft grease from repair kit into triple roller joint.

-- Press 70 g drive shaft grease from repair kit into protective joint boot.

-- Install CV boot.

-- Install clamp.