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 
• Vibration Damper Assembly Tool: T40236 
• Pneumatic Hydraulic Press: VAS6654 
• Commercially available locking ring pliers.

Disassembling 

-- 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.

• 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-.

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

• Leave the joint in the : T40236  .

-- Remove grease with a lint-free cloth.

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

-- Arrange the special tools as shown.

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 

-- 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.

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

• 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.

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-.

-- 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.

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 .