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

Special tools and workshop equipment required 

• Press Plate:VW401 
  Fig 1: Press Plate

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• Press Plate:VW402 
  Fig 2: Press Plate VW402

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• Press Piece - Rod:VW409 
  Fig 3: Identifying Press Piece - Rod VW409

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• Press Piece - Multiple Use:VW412 
  Fig 4: Identifying Press Piece - Multiple Use VW412

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• Press Piece - 37mm:VW416B 
  Fig 5: Press Piece - 37mm VW416 B

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• CV Joint Press Sleeve:VW522 
  Fig 6: CV Joint Press Sleeve VW522

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• Slide Hammer Set:VW771 
  Fig 7: Identifying Slide Hammer Set

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• Press Block:40-204A 
  Fig 8: Identifying Press Block 40 - 204 A

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• Triple Roller Assembly Tool:T40236 
  Fig 9: Identifying Triple Roller Assembly Tool T40236

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• Pneumatic Hydraulic Press:VAS 6654  , not illustrated
• Locking ring pliers, commercially available

Disassembling

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-- Clamp the drive axle -1- horizontally in a vise with protective covers over the jaws.

• Make sure the drive axle is not damaged.

-- Open the clamps -arrows-.

-- Push back the CV boot -2-.

-- Mark the installation position of the joint to the drive axle using, for example, a waterproof felt-tip pen.

-- Guide in the Triple Roller Assembly Tool:T40236  -item 2- behind the joint.

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• The guide pin -1- must rest on the outer joint -4-.

-- Move the Triple Roller Assembly Tool:T40236  -item 2- up to the stop by turning the knurled bolts -3- on the joint -4-.

• Secure the joint without play in the Triple Roller Assembly Tool:T40236  .
• Only tighten the knurled bolts hand tight.

-- Install the Slide Hammer Set:VW 771  -item 1- in the Triple Roller Assembly Tool:T40236  -item 2-.

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-- Remove the joint -1- horizontally using the Slide Hammer Set:VW771  .

• Leave the joint in the Triple Roller Assembly Tool:T40236  .

-- Mark the installation position of the drive axle -1- to the triple roller star -2- using, for example, a waterproof felt-tip pen -arrow-.

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-- Remove grease with a lint-free cloth.

-- Remove the circlip -1- with locking ring pliers -2- from the drive axle -3-.

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-- Press the triple roller star -2- off the drive axle -4-.

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1. Press Piece - Rod:VW409 
2. Triple Roller Star
3. CV Joint Press Sleeve:VW522 
4. Drive Axle
5. Press Plate:VW401 
6. Press Plate:VW402 

• The CV Joint Press Sleeve:VW522  must rest on the circlip -arrow-. The circlip is removed together with the triple roller star from the drive axle.
• The CV Joint Press Sleeve:VW522  must not touch the rollers; move the rollers to the side if necessary.

-- 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

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

-- Position the CV boot in the outer groove -arrow A-.

• The inner groove -arrow B- remains visible "identification groove" (for correct installation of CV boot).

-- Apply a thin coat of grease used in the joint to the drive axle -1- splines -arrows-.

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-- Attach the Press Block:40-204A  -item 2- to the drive axle -3-.

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• The Press Block:40-204A  must grip to the bottom of the ridge -arrow- in the drive axle.

-- Tighten the nuts -4- hand-tight.

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

-- Position the triple roller start on the shaft according to the marking.

-- Press the triple roller star -3- on the drive axle -4-.

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1. Press Piece - Multiple Use:VW412 
2. Larger inner diameter of the Press Piece - 37mm:VW 416B  toward the triple roller star.
3. Triple Roller Star
4. Drive Axle
5. The Press Block:40-204A  must attach to the bottom of the bead -arrow- in the drive axle.
6. Press Plate:VW402 
7. Press Plate:VW401 

-- Install the circlip -1- with locking ring pliers -2- on the drive axle -3-.

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• The circlip must audibly engage.
• The triple roller star -3- must lie flush on the circlip -1- with no gap.

-- Press half of the total amount of grease from the repair kit into the triple roller joint.

-- Lightly grease the roller body.

-- Press the joint -3- with a plastic mallet -2- over the triple roller star -4- in the -direction of the arrow-.

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• Be careful not to tilt the rollers.

1. Triple Roller Assembly Tool: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.

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