Overview - Drive Axle: Notes

Fig 1: Drive Axle Assembly Overview

Courtesy of AUDI OF AMERICA, LLC

1. Clamp
   • Always replace after removing
   • Tensioning. Refer to CLAMP ON TRIPLE ROLLER JOINT AND OUTER JOINT, TENSIONING .
2. CV Boot
   • If the drive axle has a peened triple roller joint, then the triple roller joint has an adapter installed.
   • The CV boot must fit in the groove and on the joint contour.
3. Clamp
   • Always replace after removing
   • Tensioning. Refer to CLAMP ON TRIPLE ROLLER JOINT AND OUTER JOINT, TENSIONING .
4. Circlip
   • Always replace after removing
   • Insert into ring groove of shaft before installation (not visible on installed joint).
   • Before installing CV joint, align the circlip in the center with opening facing upward.
5. Outer CV Joint
   • Completely replace
   • Removing. Refer to Outer CV Joint, Removing .
   • Checking using the Vehicle Diagnostic Tester. Refer to OUTER CV JOINT, CHECKING .
   • Installing. Refer to Outer CV Joint, Installing .
   • Lubricating. Refer to Grease Quantity and Type .
   • Before installing the CV joint, thinly coat the profile shaft splines with the grease used in the joint.
6. Bolt
   • Always replace after removing
   • Clean the threads in the CV joint with for example a thread tap.
   • Drive axle threaded connection, loosening and tightening. Refer to DRIVE AXLE THREADED CONNECTION, LOOSENING AND TIGHTENING .
7. Clamp
   • Always replace after removing
   • Tensioning. Refer to CLAMP ON TRIPLE ROLLER JOINT AND OUTER JOINT, TENSIONING .
8. CV Boot
   • Check for tears and scuffing
9. Clamp
   • Always replace after removing
   • Tensioning. Refer to CLAMP ON TRIPLE ROLLER JOINT AND OUTER JOINT, TENSIONING .
10. Drive Axle
    • Different versions:
      • Triple roller joint AAR 2600 i with an outer CV joint with 85.2 mm diameter.
      • Triple roller joint AAR 3300 i with an outer CV joint with 94 mm or 98.9 mm diameter.
      • Triple roller joint AAR 3700 i with an outer CV joint with 102.7 mm diameter.
    • Allocation. Refer to the parts information.
    • Removing and installing. Refer to DRIVE AXLE, REMOVING AND INSTALLING .
    • Triple roller joint allocation. Refer to Fig 2.
    • Drive axle, disassembling and assembling. Refer to DRIVE AXLE, DISASSEMBLING AND ASSEMBLING .
11. Circlip
    • Always replace after removing
    • Insert in shaft groove
12. Triple Roller Star
    • Mark the installed position for reinstallation.
    • Disassembling and assembling. Refer to DRIVE AXLE, DISASSEMBLING AND ASSEMBLING .
    • Before installing the triple roller star, thinly coat the profile shaft splines with the grease used in the joint.
13. Circlip
    • Always replace after removing
    • Insert in shaft groove
14. Bolt
    • M10: 50 Nm + 90°
    • M12: 90 Nm + 90°
    • Always replace after removing
15. Joint
    • Disassembling and assembling. Refer to DRIVE AXLE, DISASSEMBLING AND ASSEMBLING .

Triple Roller Joint Allocation

Fig 2: Determine Dimension A

Courtesy of AUDI OF AMERICA, LLC

-- Determine the dimension -A- with the clamps open and the CV boot pushed back.

• Dimension -A- = approximately 74 mm: drive axle with triple roller joint AAR 2600 i

-- Drive axle with Triple Roller Joint AAR 2600 i, disassembling and assembling. Refer to DRIVE AXLE, DISASSEMBLING AND ASSEMBLING, TRIPLE ROLLER JOINT AAR 2600 I AND AAR 3300 I .

• Dimension -A- = approximately 77 mm: drive axle with triple roller joint AAR 3300 i

-- Drive axle with Triple Roller Joint AAR 3300 i, disassembling and assembling. Refer to DRIVE AXLE, DISASSEMBLING AND ASSEMBLING, TRIPLE ROLLER JOINT AAR 2600 I AND AAR 3300 I .

• Dimension -A- = approximately 82 mm: drive axle with triple roller joint AAR 3700 i

-- Drive axle with Triple Roller Joint AAR 3700 i, disassembling and assembling. Refer to DRIVE AXLE, DISASSEMBLING AND ASSEMBLING, TRIPLE ROLLER JOINT AAR 3700I .