Drive Axle, Disassembling And Assembling, Triple Roller Joint AAR 3700I

Special tools and workshop equipment required 

• Press Plate:VW401 
• Press Plate:VW402 
• Press Piece - Rod:VW409 
• Press Piece - Multiple Use:VW412 
• Press Piece - 37mm:VW416B 
• CV Joint Press Sleeve:VW522 
• Slide Hammer Set:VW771 
• Press Block :40-204A 
• Triple Roller Assembly Tool:T40236 
• Pneumatic Hydraulic Press:VAS6654 
• Commercially available locking ring pliers.

Disassembling

Fig 1: Identifying Clamps & Protective Boot

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

-- Open the clamps -arrows-.

-- Slide back the CV boot.

-- Guide the :T40236  behind the joint.

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

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

-- Move the :T40236  until it rests on the joint by turning knurled screws -2-.

-- Install the :VW771  -3- in the :T40236  -2-.

Fig 3: Installing Slide Hammer Set VW 771 In Triple Roller Assembly Tool T40236

Courtesy of AUDI OF AMERICA, LLC

-- Remove the joint -1- horizontally with the :VW771  .

• Leave the joint in the :T40236  .

Fig 4: Drive Axle, Triple Roller Star & Mark

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-- Remove grease with a lint-free cloth.

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

Fig 5: Removing/Installing Circlip

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-- Arrange the special tools as shown.

Fig 6: Identifying Tool Set-Up

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1. :VW409 
2. Triple Roller Star
3. :VW522 
4. :VW401 
5. :VW402 

• The :VW522  must rest on the circlip -arrow-. The circlip is removed together with the triple roller star from the drive axle.
• The :VW522  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

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-- Install the :40-204A  -2- as shown.

Fig 9: Installing Press Block 40-204A And Installing New Circlip

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• The :40-204A  must attach to the bottom of the bead -arrow- in the drive axle.

-- Tighten the nuts -3- hand tight.

-- Insert the new circlip -1- up to the center of the splines.

-- 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 10: Identifying Tool Set-Up

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1. :VW412 
2. :VW416B 
3. Triple Roller Star
4. :40-204A 
5. :VW402 
6. :VW401 

• The :VW416B  faces the triple roller star with the larger inner diameter.
• The :40-204A  must attach to the bottom of the bead -arrow- in the drive axle.
• The :40-204A  must not touch the rollers; move the rollers to the side if necessary.

-- Press on the triple roller star.

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

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

Fig 11: Removing/Installing Circlip

Courtesy of AUDI OF AMERICA, LLC

-- 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.

-- Push the joint -2- over the triple roller star using a plastic mallet in direction of -arrow-. Make sure roller body does not tilt during this.

Fig 12: Pushing Joint Over Triple Roller Star Using A Plastic Hammer And Triple Roller Assembly Tool T40236

Courtesy of AUDI OF AMERICA, LLC

1. :T40236 

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