Triple Roller Joint AAR 2000, Disassembling and Assembling

Triple roller joint AAR 2000, disassembling and assembling





Special tools and equipment
^ VW 426 Tube
^ 40-204 A Block
^ 3340 Pliers

Disassembling





- Open hose clamp.
- Open clamp on shaft and slide back protective boot.





- Open out plate tabs (arrows) with a screwdriver and pry off cover.





- Mark installation position of parts 1 . . . 3.

If the parts are not marked and when assembling, the components are not brought back to their previous installation position. Then it is possible that it will be noisy when driving.

A waterproof felt tipped pen is suitable for marking.

1. Triple rotor joint housing
2. Triple roller star
3. Axle shaft
- Take O-ring -arrow- out of groove.
- Hold joint and take axle shaft out of vice.





- Remove circlip.
1. Pliers VW 161 A or available commercially

- Insert axle shaft in press.





- Hold axle shaft, then press triple roller star off axle shaft.
- Take off Triple roller star with rollers and place on a clean surface.
- Pull joint off shaft.
- Pull protective boot off shaft.
- Clean shaft, joint and groove for oil seal.

Assembling

- Slide joint protective boot onto shaft.
- Slide joint onto shaft.

Assembling star

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





- Install triple roller star onto shaft as per markings and press in to stop.
- Make sure that the pressure does not exceed 3.0 t (6614 lbs.)!
- If necessary coat axle shaft splines and star with lubricating paste G 052 142 A2.
- Insert circlip, make sure seated correctly.
- Press 60 grams (2.12 oz.) of joint grease from repair set into triple roller joint.
- Slide joint over rollers and hold.
- Press 60 grams (2.12 oz.) of joint grease from repair set into the reverse side of the triple roller joint.
- Install joint protective boot.

The ridge in the joint protective boot must seat in the joint groove.

- Now remove axle shaft from vice and tighten joint in vice.





- Insert new seal -arrow- from repair set into groove.
- Install new cover to joint.
The holes of the cover and joint must align.





- Install boot clamp.