Drive Axle With Triple Roller Joint AAR 2600i,

Drive Axle with Triple Roller Joint AAR 2600i,

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 408 A)

• Punch (VW 411)

• Sleeve (VW 416 B)

• Thrust pad (VW 447 H)

• Assembly tool (T10065)

Disassembling

- Open clamp at shaft and slide back CV boot.

- Remove the joint from the drive axle.

- Remove securing ring.

1 Pliers (commercially available) or (VW 161 A)

- Insert drive axle in vise.

- Press triple roller star off drive axle.






- 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.

Triple Roller Star, Conical Drive Axle, Installing

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

- Before installing CV joint or triple roller star, splines - A - must be lightly coated with grease used in joint.






- Install triple roller star onto shaft and press onto stop.






- Make sure that pressure does not increase above 3.0 t!

- If necessary coat drive axle splines and triple roller star with polycarbamide grease G 052 142 A2.

- Insert securing ring, be sure to fit properly.

- Slide joint piece over rollers and secure.

- Press 70 g drive shaft grease from repair kit into triple roller joint.

- Press 70 g drive shaft grease from repair kit into protective joint boot.

- Install CV boot.

- Install clamp.

Outer CV Joint, Checking






It is necessary to disassemble the joint whenever replacing the grease or if the ball surfaces show wear or damage.

Removing

- Before disassembling mark ball hub position in relation to the ball cage and housing with an electric scriber or oil stone - arrow -.

- Tilt ball hub and ball cage and remove balls one after another.

- Turn cage until two cage windows - arrow - rest on joint body.






- Lift out cage with hub.

- Swing a hub segment in a cage window.






- Fold hub out from cage.

• 6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small depressions (pitting build-up) and chafing.

• Excessive circumferential backlash in joint makes itself noticed via tip-in shock, in such cases joint should be replaced.

• Flattening and running marks of balls are no reason to replace joint.

Installing

Install in reverse order of removal. Note the following:

- Press quantity of grease specified in table into joint body.

• 90 mm diameter outer joint, grease quantities => [ Filling the Joints with Grease ] Drive Axle With 100 mm Inner CV Joint

• 98 mm diameter outer joint, grease quantities => [ Filling the Joints with Grease ] Drive Axle With 108 mm Inner CV Joint

- Insert cage with hub into joint body.

• Cage must be installed laterally correct.

- Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body must be established again.

- Install new circlip in shaft.

- Distribute remaining grease in the joint boot.