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

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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 Triple Roller Assembly Tool:T40084 is used for the triple roller joint AAR 2600 i.

The Triple Roller Assembly Tool:T40018 is used for the triple roller joint AAR 3300 i.

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:VW408A

Fig 3: Press Piece - Rod
Courtesy of AUDI
Press Piece - Rod:VW411

Fig 4: Press Piece - Rod
Courtesy of AUDI
Press Piece - 37mm:VW416B

Fig 5: Press Piece - 37mm VW416 B
Courtesy of AUDI
Press Piece - Multiple Use:VW447H

Fig 6: Press Piece - Multiple Use
Courtesy of AUDI
Slide Hammer Set:VW771

Fig 7: Identifying Slide Hammer Set
Courtesy of AUDI
Clamping Pliers:V.A.G 1682A with Clamping Pliers - Jaws:V.A.G 1682A/1

Fig 8: Clamping Pliers - Jaws
Courtesy of AUDI
Tripod Joint Tool:T10065

Fig 9: Assembly Tool T10065
Courtesy of AUDI
Triple Roller Assembly Tool:T40018 for drive axles with triple roller joint AAR 3300 i

Fig 10: Assembly Device T40018 For Triple Roller Joint AAR 3300 i
Courtesy of AUDI
Triple Roller Assembly Tool:T40084 for drive axles with triple roller joint AAR 2600 i

Fig 11: Assembly Device T40084 For Triple Roller Joint AAR 2600 i
Courtesy of AUDI
Pneumatic Hydraulic Press:VAS 6654 , not illustrated
Locking ring pliers, commercially available

Disassembling

Fig 12: 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:T40018 or Triple Roller Assembly Tool:T40084 behind the joint.

Fig 13: 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.

-- Bring the Triple Roller Assembly Tool:T40018 or Triple Roller Assembly Tool:T40084 to rest on the joint by turning the knurled bolts -2-.

NOTE:

The joint must be secured without any play in the Triple Roller Assembly Tool:T40018 or Triple Roller Assembly Tool:T40084 .

Only tighten the knurled bolts hand tight.

-- Install the Slide Hammer Set:VW771 in the Triple Roller Assembly Tool:T40018 or Triple Roller Assembly Tool:T40084 .

Fig 14: Identifying Slide Hammer VW 771 Installed In Assembly/Removal Tool T40018

Courtesy of AUDI

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

Leave the joint in the Triple Roller Assembly Tool:T40018 or Triple Roller Assembly Tool:T40084 .

Fig 15: 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 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 cleaning cloth.

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

Fig 16: Removing/Installing Circlip

Courtesy of AUDI

-- Arrange the special tools as shown.

Fig 17: Identifying Tool Set Up/Assembly

Courtesy of AUDI

Assembly Tool:T10065/1
Triple Roller Assembly Tool:T10065/5
Press Plate:VW401
Press Piece - Rod:VW408A
Press Plate:VW402

The Triple Roller Assembly Tool:T10065/5 must rest on the base body of the triple roller star.
The Triple Roller Assembly Tool: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

Fig 18: 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 19: Apply Grease

Courtesy of AUDI

-- 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 20: Identifying T10065/6 And Making Sure It Attaches To Bead At Bottom In Drive Axle

Courtesy of AUDI

Assembly Tool:T10065/1
Triple Roller Assembly Tool:T10065/6
Press Plate:VW401
Press Piece - 37mm:VW416B
Press Piece - Multiple Use:VW447H
Press Piece - Rod:VW411
Press Plate:VW402

The Triple Roller Assembly Tool:T10065/6 must attach to the bottom of the bead -arrow- in the drive axle.
The Triple Roller Assembly Tool:T10065/6 must not touch the rollers; move the rollers to the side if necessary.

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

Fig 21: Removing/Installing Circlip

Courtesy of AUDI

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

Fig 22: Pressing Joint Over Triple Roller Star Using Plastic Hammer

Courtesy of AUDI

NOTE:

Triple Roller Assembly Tool: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 .