Drive Axle With Triple Roller Joint AAR2600I/AAR3300I, Servicing, Mounted On Transmission Stub Shaft

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 
• 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: VW771 
• Puller - Driveshaft: T10382 
• Puller - Driveshaft: T10382/1 
• Puller - Driveshaft - Spindles: T10382/2 
• Three-Arm Puller : VAS251205  (previously Kukko 45-2)

Removing the Outer CV Joint 

-- Secure the drive axle with protective covers in a vise clamp.

-- Fold back boot.

-- Align the : T10382  so that the flat side of the : T10382/1  faces the : T10382/2  .

-- Attach the : T10382  to the : VW771  .

-- Remove the CV joint from the drive axle using the : T10382  and : VW771  .

1. : T10382/1 
2. : T10382/2 

Installing the Outer CV Joint: 

-- Install the new circlips.

-- Slide new CV boot onto drive axle if necessary.

-- Use a plastic hammer to install it on the shaft until the locking ring locks secure.

Disassembling: 

-- Open clamping sleeve on inner joint and slide protective boot back from adapter.

-- Remove the joint from the drive axle.

-- Remove securing ring.

1 -  Pliers (commercially available)

-- Insert drive axle in vise.

-- Press the triple roller star off the drive shaft.

-- 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.

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

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

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

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

-- Press half of the joint grease from the repair set into the triple roller joint.

-- Slide joint piece over rollers and secure.

-- Press the remaining half of the drive axle grease from the repair kit into the rear side of the triple roller joint.

-- Install CV boot.

Triple Roller Star, Cylinder Drive Shaft, Installing: 

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

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

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

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

-- Press half of the joint grease from the repair set into the triple roller joint.

-- Slide joint piece over rollers and secure.

-- Press the remaining half of the drive axle grease from the repair kit into the rear side of the triple roller joint.

-- Slide the protective boot onto the adapter and ensure the boot engages correctly in the groove on the adapter -arrow-.

-- Mount and tension the clamp until a proper seal is guaranteed.

Tightening Clamp on Outer Joint: 

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

-- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).

• Tightening specification: 25 Nm.

Tensioning Clamp on Small Diameter 

Removing the Cap from the Triple Roller Joint:

1. : VAS251205 
2. : VW447H 

Mounting the Cap onto the Triple Roller Joint: 

1. : T10243 

• Mount the cap far enough onto the joint until the ridge -arrow A- fits into the groove -arrow B-.