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

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Special tools and workshop equipment required

Press Plate:VW401

Fig 1: Press Plate
Courtesy of AUDI
Press Plate:VW402

Fig 2: Press Plate VW402
Courtesy of AUDI
Press Piece - Rod:VW409

Fig 3: Identifying Press Piece - Rod VW409
Courtesy of AUDI
Press Piece - Multiple Use:VW412

Fig 4: Identifying Press Piece - Multiple Use VW412
Courtesy of AUDI
Press Piece - 37mm:VW416B

Fig 5: Press Piece - 37mm VW416 B
Courtesy of AUDI
CV Joint Press Sleeve:VW522

Fig 6: CV Joint Press Sleeve VW522
Courtesy of AUDI
Slide Hammer Set:VW771

Fig 7: Identifying Slide Hammer Set
Courtesy of AUDI
Press Block :40-204A

Fig 8: Identifying Press Block 40 - 204 A
Courtesy of AUDI
Triple Roller Assembly Tool:T40236

Fig 9: Identifying Triple Roller Assembly Tool T40236
Courtesy of AUDI
Pneumatic Hydraulic Press:VAS 6654 , not illustrated
Locking ring pliers, commercially available

Disassembling

Fig 10: Identifying Clamps & Protective Boot

Courtesy of AUDI

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

NOTE:

Make sure the drive axle is not damaged.

-- Open the clamps -arrows-.

-- Slide back the CV boot.

CAUTION:

There is a risk of noise while driving due to a changed installation position.

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

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

Fig 11: Bringing Guide Pins Into Contact With Joint By Turning Knurled Thumb Screws

Courtesy of AUDI

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

-- Move the Triple Roller Assembly Tool until it rests on the joint by turning knurled screws -2-.

NOTE:

Secure the joint without play in the Triple Roller Assembly Tool:T40236 .

Only tighten the knurled bolts hand tight.

-- Install the Slide Hammer Set:VW771 -3- in the Triple Roller Assembly Tool:T40236 -2-.

Fig 12: Installing Slide Hammer Set VW 771 In Triple Roller Assembly Tool T40236

Courtesy of AUDI

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

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

Fig 13: Drive Axle, Triple Roller Star & Mark

Courtesy of AUDI

CAUTION:

There is a risk of noise while driving due to a changed installation position.

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

-- Remove grease with a lint-free cleaning cloth.

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

Fig 14: Removing/Installing Circlip

Courtesy of AUDI

-- Arrange the special tools as shown.

Fig 15: Identifying Tool Set-Up

Courtesy of AUDI

Press Piece - Rod:VW409
Triple Roller Star
CV Joint Press Sleeve:VW522
Press Plate:VW401
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.

-- 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 16: Circlip (Snap Ring) & Positioning Protective Joint Boot

Courtesy of AUDI

-- 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 17: Apply Grease

Courtesy of AUDI

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

Fig 18: Installing Press Block 40-204A And Installing New Circlip

Courtesy of AUDI

The Press Block: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 19: Identifying Tool Set-Up

Courtesy of AUDI

Press Piece - Multiple Use:VW412
Press Piece - 37mm:VW416B
Triple Roller Star
Press Block :40-204A
Press Plate:VW402
Press Plate:VW401

The Press Piece - 37mm:VW 416B faces the triple roller star with the larger inner diameter.
The Press Block:40-204A must attach to the bottom of the bead -arrow- in the drive axle.
The Press Block: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 20: Removing/Installing Circlip

Courtesy of AUDI

-- 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 -arrow-. Make sure roller body does not tilt during this.

Fig 21: Pushing Joint Over Triple Roller Star Using A Plastic Hammer And Triple Roller Assembly Tool T40236

Courtesy of AUDI

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.

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