Drive Axle, Triple Roller Joint AAR3300I

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Special tools and workshop equipment required

Thrust PlateVW401
Thrust PlateVW402
Press Piece - Rod VW408A
Press Piece - RodVW411
Press Piece - 37mmVW416B
Press Piece - Multiple UseVW447H
Hose Clamp PliersVAG1275
Torque Wrench 5-50NmVAG1331
Torque Wrench 40-200NmVAG1332
CV Joint Boot Clamp ToolVAG1682
Assembly ToolT10065
Slide Hammer SetVW771
PullerT10382

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.

PlateT10382/1
SpindlesT10382/2

Installing the Outer CV Joint

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Plate Spring
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.

-- Pull off CV boot from shaft.

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

Fig 4: Identifying Triple Roller Star Pressed Off From Driveshaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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.

-- Install clamp.

Fig 7: 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-.

-- Attach CV Joint Boot Clamp ToolVAG1682 as shown in illustration below. When doing this, make sure that edges of clamping pliers are seated in corners -arrows B- of clamp.

Fig 8: Identifying Tensioning Clamps On Larger Diameter Of Inner Joint

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 ToolVAG1682.

Tightening specification: 25 Nm.

Use torque wrench -C- with adjustment range 5..50 Nm (for example Torque Wrench 5-50NmVAG1331).

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.

-- Attach CV Joint Boot Clamp ToolVAG1682 as shown in illustration below. When doing this, make sure that edges of clamping pliers are seated in corners -arrows B- of clamp.

Fig 9: Attaching CV Joint Boot Clamp Tool V.A.G 1682

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 10: Attaching CV Joint Boot Clamp Tool VAG 1682

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.