Disassembly and Assembly
Drive Axle with Triple Roller Joint AAR 2600i
Special tools, testers and auxiliary items required
• Clamp Tensioner (V.A.G1682A)
• Hose Clip Pliers (V.A.G1275)
Filling the Joints with Grease
• Grease joint again when replacing protective joint boot.
1 - Bolt
• Always replace if removed.
• Different versions, allocation, refer to the Parts Catalog
• Hex bolt = 200 Nm + 180° additional turn => [ Hex Bolt between Drive Axle and Wheel Hub, Loosening and Tightening ] Hex Bolt Between Drive Axle and Wheel Hub, Loosening and Tightening.
• Twelve-point bolt with ribs = 70 Nm + 90° additional turn, refer to => [ Twelve-Point Bolt with Ribs, Loosening and Tightening, Drive Axle to Wheel Hub ] Twelve-Point Bolt With Ribs, Loosening and Tightening, Drive Axle to Wheel Hub.
• Twelve-point bolt without ribs = 200 Nm +180° additional turn, loosening and tightening, refer to => [ Twelve-Point Bolt without Ribs, Loosening and Tightening, Drive Axle to Wheel Hub ] Twelve-Point Bolt Without Ribs, Loosening and Tightening, Drive Axle to Wheel Hub
• Before installing, clean the threads in the CV joint with a tap.
2 - Clamp
• Replace
• Tensioning, refer to => [ Large Clamps for Rubber Protective Joint Boots, Tensioning ] or => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ]
3 - CV Boot
• Check for tears and scuffing
4 - Clamp
• Replace
• Tensioning, refer to => [ Large Clamps for Rubber Protective Joint Boots, Tensioning ] or => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ]
5 - Profile shaft
6 - Clamp
• Replace
• Tensioning, refer to => [ Large Clamps for Rubber Protective Joint Boots, Tensioning ] or => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ]
7 - CV Boot for Triple Roller Joint
• Check for tears and scuffing
8 - Triple Roller Star with Rollers
• Chamfer - arrow - faces splines of drive shaft
• When installing triple roller star on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
9 - Locking Ring
• Replace
10 - Bolt
• Pre-tightening specification: 10 Nm and diagonally
• Tightening specification M8: 40 Nm and diagonally
• Tightening specification M10: 70 Nm and diagonally
• Always replace if removed.
11 - Bolted joint
12 - Clamp
• Replace
• Tensioning, refer to => [ Large Clamps for Rubber Protective Joint Boots, Tensioning ] or => [ Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning ]
13 - Plate Spring
• Installed position, refer to => [ Location of Spacer Ring and Plate Spring ]
14 - Spacer ring (plastic)
• Installed position, refer to => [ Location of Spacer Ring and Plate Spring ]
15 - Locking Ring
• Replace
• Insert in shaft groove
16 - Outer CV joint
• Replace only as complete unit.
• Removing, refer to => [ Removing the Outer CV Joint ]
• Installing
• Checking, refer to => [ Outer CV Joint, Checking ] Outer CV Joint, Checking
• grease => table, page
• When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
Removing the Outer CV Joint
- Remove the CV joint from the drive axle by hitting it with a light alloy hammer.
Location of Spacer Ring and Plate Spring
1 Plate Spring
2 Spacer ring (plastic)
Outer CV Joint, Installing
- Before installing CV joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
- Install old drive shaft bolt in joint as shown in the illustration.
- Drive joint onto shaft with plastic hammer until circlip engages.
Rubber Protective Joint Boot, Ventilating
The CV boot is frequently pressed in when placed on the CV joint body. This creates a vacuum in the CV boot, which pulls a fold inward when the car is driven - arrow -.
Therefore, observe the following:
- Before clamping the clamping sleeves, balance pressure by raising protective joint boot.
Large Clamps for Rubber Protective Joint Boots, Tensioning
Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning
- Position pliers (V.A.G 1682) as shown in illustration. When doing this, make sure that edges of clamping pliers are seated in corners - arrows B - of clamp.
- Tighten the hose clamp by turning spindle - A - using a torque wrench (do not tilt clamping pliers).
• Tightening Specifications: 20 Nm
• Be sure thread of spindle in clamping pliers moves freely. Grease with MOS2 grease, if necessary.
• If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.
Small Clamps for Rubber Protective Joint Boots, Tensioning
