Drive Axle With Triple Roller Joint AAR 2900
Drive Axle with Triple Roller Joint AAR 2900
Special tools, testers and auxiliary items required
• Thrust plate (VW 401)
• Thrust plate (VW 402)
• Punch (VW 408 A)
• Punch (VW 411)
• Tube 37 mm dia. (VW 416 B)
• Thrust pad (VW 447 H)
• Hose clamp pliers (V.A.G 1275)
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1332)
• CV joint boot clamp tool (V.A.G 1682)
• Assembly tool (T10065)
Grease Quantities and Types
Grease filling of joints with high temperature grease.
When replacing CV boot add grease to joint, if necessary.
Disassembling
- Open clamp of joint piece and slide back CV joint boot.
- Open clamp at shaft and slide back CV boot.
- Drive slot-head screwdriver or similar tool in cover and pry off cover.
If cover cannot be pried off, it is recommended to drive screwdriver in on the opposite side, then pry off cover.
- Mark installation position of parts 1 through 3 with lines.
It is only necessary to mark when the rollers can be pulled off triple roller star.
If they are not marked and are not reinstalled in their previously installed positions, noises may occur later during driving operation.
A waterproof felt pen is well-suited for marking.
- Remove rubber ring - arrow - from groove.
1 Triple roller joint housing
2 Triple roller star
3 Axle shaft
- Secure joint piece and remove drive axle from vise.
Make sure that roller does not slip out of triple roller star and fall to the ground!
- Hold drive axle with joint piece in vertical position and now slowly slide joint piece back using the other hand.
- Mark installation position of rollers - 1 - to triple roller star - 2 - using felt-tip marker.
- Remove rollers - 1 - and set aside on a clean surface.
- Remove securing ring.
1 Pliers (commercially available)
- Insert axle shaft in vise.
- Secure axle shaft then press off triple roller star from drive axle.
- Pull off joint piece with CV joint boot from axle.
- Clean shaft, joint piece and groove for oil seal.
Assembling
- Slide small clamp for CV boot onto shaft.
- Slide CV boot onto shaft.
- Slide joint piece onto shaft.
Mount triple roller star.
Chamfer on star faces toward shaft, it facilitates assembly.
- Connect triple roller star on shaft and press on up to stop.
- Make sure that pressure does not increase above 3.0 t!
- If necessary, coat drive axle splines and triple roller star with solid lubricant (G 052 142 A2 ).
- Insert securing ring, be sure to fit properly.
- Install rollers according to markings on triple roller star.
- Slide joint piece over rollers and secure.
- Press 70 grams of drive axle grease from repair kit into triple roller joint.
- Press 70 grams of drive axle grease from repair kit into back of triple roller joint and CV joint boot.
- Insert round seal - 3 - from repair kit into groove of triple roller joint - 4 -.
1 Circlip
2 Cover from repair kit
3 Sealing ring
4 Triple roller joint
- Insert axle shaft in vise.
- Press cover - 1 - far enough into triple roller joint so that securing ring can be inserted.
- Insert securing ring, be sure to fit properly.
Securing ring must engage audibly!
- Install CV boot.
- Position triple roller joint approximately in center of slide path, see distance between min. and max.
- Hold triple roller joint in this position and lift CV joint boot - arrow -.
This dissipates any vacuum created within the CV joint boot.
- Mount clamp.
• Position the crimping tab - arrow A - of the clamp between mounting flanges of joint piece - arrows B -. This will facilitate threading the socket head bolts during installation of the drive axle.
- Tighten clamp using hose clamp pliers (V.A.G1275).
- Tighten small clamp using hose clamp pliers (V.A.G1275).
