Drive Axle, Disassembling And Assembling, Triple Roller Joint AAR 2600 I And AAR 3300 I

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 
• Slide Hammer Set:VW771 
• Clamping Pliers:VAG1682A  with Clamping Pliers - Jaws:VAG1682A/1 
• Tripod Joint Tool:T10065 
• Triple Roller Assembly Tool:T40018  for drive axles with triple roller joint AAR 3300 i
• Triple Roller Assembly Tool:T40084  for drive axles with triple roller joint AAR 2600 i
• Pneumatic Hydraulic Press:VAS6654 
• Commercially available locking ring pliers.

Disassembling

Fig 1: Identifying Clamps & Protective Boot

Courtesy of AUDI OF AMERICA, LLC

-- Clamp the drive axle horizontally in a vise with protective covers.

-- Open the clamps -arrows-.

-- Slide back the CV boot.

-- Guide the :T40018  or :T40084  behind the joint.

Fig 2: Bringing Guide Pins Into Contact With Joint By Turning Knurled Thumb Screws

Courtesy of AUDI OF AMERICA, LLC

• The guide pins -1- must rest on the outer joint.

-- Bring the :T40018  or :T40084  to rest on the joint by turning the knurled bolts -2-.

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

Fig 3: Identifying Slide Hammer VW 771 Installed In Assembly/Removal Tool T40018

Courtesy of AUDI OF AMERICA, LLC

-- Remove the joint horizontally with the :VW771  .

• Leave the joint in the :T40018  or :T40084  .

Fig 4: Drive Axle, Triple Roller Star & Mark

Courtesy of AUDI OF AMERICA, LLC

-- Remove grease with a lint-free cloth.

-- Remove the circlip with locking ring pliers -1-.

Fig 5: Removing/Installing Circlip

Courtesy of AUDI OF AMERICA, LLC

-- Arrange the special tools as shown.

Fig 6: Identifying Tool Set Up/Assembly

Courtesy of AUDI OF AMERICA, LLC

1. :T10065/1 
2. :T10065/5 
3. :VW401 
4. :VW408A 
5. :VW402 

• The :T10065/5  must rest on the base body of the triple roller star
• The :T10065/5  must not touch the rollers; move the rollers to the side if necessary.

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

-- Remove the CV boot.

-- Remove the grease on the shaft splines.

-- Check the roller body and ball cage for wear.

-- Clean drive axle and housing.

Assembling

Fig 7: Circlip (Snap Ring) & Positioning Protective Joint Boot

Courtesy of AUDI OF AMERICA, LLC

-- Slide on the small clamp with the CV boot.

-- Position the CV boot between the -arrows- on the drive axle.

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

Fig 8: Apply Grease

Courtesy of AUDI OF AMERICA, LLC

-- Place the triple roller star on the shaft according to the applied mark and drive on all the way.

-- Arrange the special tools as shown.

Fig 9: Identifying T10065/6 And Making Sure It Attaches To Bead At Bottom In Drive Axle

Courtesy of AUDI OF AMERICA, LLC

1. :T10065/1 
2. :T10065/6 
3. :VW401 
4. :VW416B 
5. :VW447H 
6. :VW411 
7. :VW402 

• The :T10065/6  must attach to the bottom of the bead -arrow- in the drive axle.
• The :T10065/6  must not touch the rollers; move the rollers to the side if necessary.

-- Install the circlip with locking ring pliers -1-.

Fig 10: Removing/Installing Circlip

Courtesy of AUDI OF AMERICA, LLC

• The circlip must engage audibly, and the triple roller star must lie on the circlip with no gap.

-- Press the drive axle grease from the repair kit into the rear side of the triple roller joint. Refer to Grease Quantity and Type .

-- Lightly grease the roller body.

-- Press the joint over the triple roller star using a plastic mallet in direction of -arrow-. Make sure roller body does not tilt during this.

Fig 11: Pressing Joint Over Triple Roller Star Using Plastic Hammer

Courtesy of AUDI OF AMERICA, LLC

-- Push remaining amount of grease in the CV boot.

-- Make sure the CV boot is seated on the joint correctly.

• The CV boot must fit in the groove and on joint contour.

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