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 
• 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 the : T40018  -2- behind the joint.

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

-- Move the : T40018  -2- up to the stop by turning the knurled bolts -3- on the joint -4-.

• Secure the joint without play in the : T40018  .
• Only tighten the knurled bolts hand tight.

-- Install the : VW771  -1- in the : T40018  -2-.

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

• Leave the joint in the : T40018  .

-- 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. : VW409 
2. Triple Roller Star
3. : VW522 
4. Drive Axle
5. : VW401 
6. : 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.

-- 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 : 40-204A  -2- to the drive axle -3-.

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• The : 40-204A  must attach to the bottom of the bead -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. : VW412 
2. : VW416B  , with the larger inner diameter facing the triple roller star.
3. Triple Roller Star
4. Drive Axle
5. The : 40-204A  must attach to the bottom of the bead -arrow- in the drive axle.
6. : VW402 
7. : 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. : T40018 

-- 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 .