Drive Axle, Triple Roller Joint AAR2600I

Special tools and workshop equipment required 

• Thrust Plate VW 401
• Thrust Plate VW 402
• Press Piece - Rod VW408A
• Press Piece - Rod VW 411
• Press Piece - 37mm VW416B
• Press Piece - Multiple Use VW 447H
• Hose Clamp Pliers VAG 1275
• Torque Wrench 5-50 Nm VAG 1331
• Torque Wrench 40-200 Nm VAG 1332
• CV Joint Boot Clamp Tool VAG 1682
• Assembly Tool T10065
• Slide Hammer Set VW 771
• Puller T10382

Removing the Outer CV Joint 

-- Secure the drive axle with protective covers in a vise clamp.

-- Fold back boot.

-- Align the PullerT10382 so that the flat side of the PlateT10382/1 faces the SpindlesT10382/2.

-- Attach the PullerT10382 to the Slide Hammer SetVW771.

-- Remove the CV joint from the drive axle using the PullerT10382 and Slide Hammer SetVW771.

Fig 1: Identifying Outer CV Joint

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Plate T10382/1
2. Spindles T10382/2

Installing the Outer CV Joint

Fig 2: Identifying Dished Washer And Thrust Washer On Outer Joint

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Plate Spring
2. Thrust Ring

-- Install the new circlips.

-- Slide new CV boot onto drive axle if necessary.

-- Use a plastic hammer to install it on the shaft until the locking ring locks secure.

Disassembling

-- Open both clamps at inner joint and slide back CV boot.

-- Remove joint from drive axle.

-- Remove securing ring.

Fig 3: Identifying Removal Of Circlip Using Pliers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1 -

Pliers (commercially available)

-

or Circlip PliersVW161A

-- Insert drive axle in vise.

-- Press the triple roller star off the drive shaft.

Fig 4: Identifying Triple Roller Star Pressed Off From Driveshaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull off CV boot from shaft.

-- Clean shaft, joint and groove for oil seal.

Assembling

-- 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 5: 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 pasteG 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 6: 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 PasteG 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.