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

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Press Plate: VW401
Press Plate: VW402
Press Piece - Rod: VW408A
Press Piece - Rod: VW411
Press Piece - 31.5mm: VW416B
Press Piece - Multiple Use: VW447H
Slide Hammer Set: VW771
Clamping Pliers: VAG1682A with Clamping Pliers - Jaws: VAG1682A/1
Tripod Joint Tool: T10065
Assembly Tool: T10065/1
Triple Roller Assembly Tool: T10065/5
Triple Roller Assembly Tool: T10065/6
Triple Roller Assembly Tool: T40018 for driveshafts with triple roller joint AAR 3300 i
Triple Roller Assembly Tool: T40084 for driveshafts with triple roller joint AAR 2600 i
Pneumatic Hydraulic Press: VAS6654
Commercially available locking ring pliers.

NOTE:

The procedure for drive axles with triple roller joint AAR 2600 i and AAR 3300 i is the same, but with the following difference:

The : T40084 is used for the triple roller joint AAR 2600 i.

The : T40018 is used for the triple roller joint AAR 3300 i.

Disassembling

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

NOTE:

Make sure the drive axle is not damaged.

-- Open the clamps -arrows-.

Fig 1: Identifying Clamps & Protective Boot

Courtesy of AUDI OF AMERICA, LLC

-- 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 : 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-.

NOTE:

The joint must be secured without any play in the : T40018 or : T40084 .

Only tighten the knurled bolts hand tight.

-- 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

CAUTION:

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

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

-- 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

: T10065/1
: T10065/5
: VW401
: VW408A
: 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

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

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

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

Courtesy of AUDI OF AMERICA, LLC

-- 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

: T10065/1
: T10065/6
: VW401
: VW416B
: VW447H
: VW411
: 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 the direction of the -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

NOTE:

: T40018 is shown in the example.

-- 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 .