Drive Axle With Triple Roller Joint AAR 2900, Servicing

Drive axle with triple roller joint AAR 2900, servicing
Special tools and equipment





^ VW416B tube, 37mm dia.
^ VW412 punch
^ VW 426 pipe piece
^ 3110 press support
^ Kukko 12 -1 Removal tool
^ Matra 2050 press tool





^ VAG1275 pliers
^ VW161A circlip pliers
^ 3207 pressing screw

Drive axle with triple roller joint, servicing

Note: Types and grease specifications of triple roller drive axle:





Outer joint:
^ Diameter 98 mm G 000 633
Triple roller joint:
^ G 000 605

When replacing CV boot, grease joint anew.





1. Hex bolt
^ Always replace after disassembly
Tightening torques:
Bolt M 16:
^ 190 Nm plus additional 180° (1/2 -turn)
Observe assembly notes when removing
Observe assembly notes when installing
2. CV boot for outer Constant Velocity (CV) joint
^ Check for tears and scuffing
^ Before tightening hose clamp, briefly raise CV boot to allow pressure to equalize Fig. 3
^ Different versions in rubber or hytrel
3. Clamp
^ Different versions for CV boot in rubber or hytrel
^ Always replace
4. Drive axle
5. Clamp
^ Always replace
6. Joint piece
7. Socket-head bolt
^ M10 x 20: 70 Nm
8. Triple roller connection
^ Chamfer (arrow) faces splines of drive axle
9. Snap ring
^ Always replace
^ insert in groove on shaft
10. Sealing ring
^ There is a new seal in the repair kit; must be replaced.
11. Cover
^ Always replace
6 Destroyed during removal.
^ A modified cover is provided in the repair kit.
12. Clamp
^ Always replace
^ Tightening refer to Fig. 1
^ There may be different clamps, depending on construction. Also mountable using 3340 pliers.
^ See Parts Supplier
13. Boot for triple roller joint
14. Clamp
^ Always replace
^ Tightening refer to Fig. 1
15. Dished washer
^ Installation position Fig. 4
16. Spacer ring (plastic)
^ Installation position Fig. 4
17. Snap ring
^ Always replace
^ Insert in ring groove of shaft before installation (not visible on installed joint)
15. Outer CV joint
^ Replace only as complete unit
^ Press off refer to Fig. 2
^ Installing:
Use plastic hammer to pound joint onto shaft until snap ring snaps in.

The Instructions for Fig.1 apply only to stainless steel tensioning clamps!
Rubber CV boot are clamped on with VAG1275 pliers.





Fig. 1 Tighten clamp on outer joint
^ Apply VAG1 682 CV boot clamping pliers as shown in figure. Be sure that edges of clamping pliers are seated in corners (arrows -B-) of hose clamp.
^ Tighten hose clamp by turning spindle with a torque wrench (do not tilt clamping pliers).

Note:
^ Tightening torque: 20 Nm.
^ Use torque wrench with adjustment range from 5 to 50 Nm (e.g. VAG1331).
^ Be sure thread of spindle in clamping pliers moves freely. Grease with MoS 2 grease, if necessary.
^ If it does not move freely, e.g. due to dirt in thread, the required clamp tension will not be achieved at the specified torque.





Fig. 2 Pressing off outside Constant Velocity (CV) joint
^ Clamp drive axle in vise with protective pads.
^ Take off big hose clamp and pull back CV boot
^ Screw special tool into joint bolt until Constant Velocity (CV) joint can be removed.





Fig. 3 Venting CV boot
Only affects rubber CV boots
Installing the CV boot can create a vacuum in the joint
This vacuum pulls a fold inward when the car is driven (arrow).
Note the following:
^ Before tightening hose clamp, raise CV boot to allow pressure to equalize.





Fig. 4 Installed position of spacer ring and dished washer (wheel side)
1. Dished washer
2. Spacer ring (plastic)





Fig. 5 Tighten clamp on Inner joint