Drive Axle, Triple Roller Joint AAR3300I: Assembling

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, 2013 Volkswagen Beetle, and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

-- Slide small clamp for joint protective boot onto shaft.

-- Slide CV boot onto shaft.

-- Slide joint piece onto shaft.

Mount Triple Roller Star

Conical-Type Drive Axle

The chamfer on triple roller star faces toward shaft, this is used as an assembly aid.

-- Connect triple roller star on shaft and press on up to stop.

Fig 1: Identifying Installation Of Triple Roller Star Onto Shaft And Press Onto Stop

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Make sure the pressure does not increase above 3.0 t.

-- If necessary, coat the drive shaft splines and triple roller star with Lubricating Paste G 052 142 A2.

-- Insert securing ring, be sure to fit properly.

-- Press half of the joint grease from the repair set into the triple roller joint.

-- Slide joint piece over rollers and secure.

-- Press the remaining half of the drive axle grease from the repair kit into the rear side of the triple roller joint.

-- Install CV boot.

Mount Triple Roller Star

Cylindrical-Type Drive Axle

-- Connect triple roller star on shaft and press on up to stop.

Fig 2: Identifying Triple Roller Star Axle Shaft Pressed With Cylindrical Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Make sure the pressure does not increase above 3.0 t.

-- If necessary, coat the drive shaft splines and triple roller star with lubricating paste G 052 142 A2.

-- Insert securing ring, be sure to fit properly.

-- Press half of the joint grease from the repair set into the triple roller joint.

-- Slide joint piece over rollers and secure.

-- Press the remaining half of the drive axle grease from the repair kit into the rear side of the triple roller joint.

-- Install CV boot.

-- Push the protective boot onto the joint and mount the clamp. Refer to Figure.

-- Install clamp.

Fig 3: Clamping Ear Of Clamp Placed Between Fixing Flanges From Joint

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

For a better alignment of the multi-point socket head bolts when mounting the axle shaft, it is necessary that the clamping ear of the clamp -arrow A- is placed between the fixing flanges from the joint -arrows B-.

Fig 4: Identifying Tensioning Clamps On Larger Diameter Of Inner Joint

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Attach CV Joint Boot Clamp Tool VAG1682 as shown in illustration. When doing this, make sure that edges of clamping pliers are seated in corners -arrows B- of clamp.

-- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).

NOTE:

The hard material of the joint boot (compared to rubber) makes it necessary to use a stainless steel hose clamp. It is only possible to tighten the hose clamp with CV Joint Boot Clamp Tool VAG1682.

Tightening specification: 25 Nm.

Use torque wrench -C- with adjustment range 5..50 Nm (for example Torque Wrench 5-50Nm VAG1331).

Be sure thread of spindle -A- of clamp tool moves freely. Grease with MOS 2 grease if necessary.

If the thread is tight for example dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.

Fig 5: Attaching CV Joint Boot Clamp Tool V.A.G 1682

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Attach CV Joint Boot Clamp Tool VAG1682 as shown in illustration. When doing this, make sure that edges of clamping pliers are seated in corners -arrows B- of clamp.

-- Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).

Fig 6: Attaching CV Joint Boot Clamp Tool VAG 1682

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.