Drive Axle With Triple Roller Joint AAR 3300I, Servicing (Bolted Flange / Splines on Inner Joint
Drive axle with triple roller joint AAR 3300i, servicing (bolted flange / splines on inner joint)
Grease filling of joints
Note: Regrease joint when replacing boot.
1 - Hex bolt with washer
^ Always replace if removed
^ Loosening and tightening
2 - Hose clamp
^ Always replace
^ Tightening, or
3 - Boot for CV joint
^ Check for tears and scuffing
4 - Hose clamp
^ Always replace
^ Tightening
5 - Axle shaft
6 - Hose clamp
^ Always replace
^ Tightening, or
7 - Boot for CV joint
^ Check for tears and scuffing
8 - Triple roller connection with rollers
^ Chamfer - arrow - faces toward drive axle splines
9 - Circlip
^ Always replace
^ Insert in groove on shaft
10 - Socket-head bolt
^ Initial tightening torque: 10 Nm
^ Tightening torque(M8): 40 Nm
^ Tightening torque(M10): 70 Nm
11 - Joint body (version with splines)
^ Before installing, grease splines on stub shaft with G052735
12 - Circlip
^ Always replace
^ Insert in groove on shaft
13 - Joint body (version with bolted flange)
14 - Hose clamp
^ Always replace
^ Tightening
15 - Convex washer
^ Installation position
16 - Spacer ring (plastic)
^ Installation position
17 - Circlip
^ Always replace
^ Insert in groove on shaft
18 - Outer constant velocity (CV) joint
^ Replace only as complete unit
^ Removing
^ Greasing: see table
^ Installing:
^ Drive joint onto shaft with plastic hammer until circlip engages
Removing outer constant velocity joint
- Drive CV joint off drive axle with a firm blow from an aluminum hammer.
Installation position of spacer ring and convex washer
1 - Convex washer
2 - Spacer ring (plastic)
Venting rubber boot
The CV joint boot is often squashed when it is installed on the joint body. This creates a partial vacuum inside the boot which draws in a fold - arrow - while driving.
Please note the following:
- Before tightening the hose clamps, vent the boot to equalize pressure by briefly lifting the lip.
Tightening large hose clamp for rubber boot
Tightening stainless-steel hose clamps for Hytrel boots
- Apply pliers V.A.G 1682 as shown. Make sure that the jaws of the pliers seat in the ends of the hose clamp - arrows B -.
- Tighten hose clamp by turning spindle - A - with torque wrench (keep pliers straight).
^ Tightening torque: 20 Nm
Note:
^ Make sure thread of spindle on pliers moves freely. Lubricate with MoS2 grease if necessary.
^ If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clip when applying the specified tightening torque.
Tightening small hose clip for rubber boot
Disassembling and assembling triple roller joint AAR 3300i
Special tools, testers and auxiliary items required
^ Thrust plate VW401
^ Thrust plate VW402
^ Punch VW408A
^ Punch VW411
^ Tube 37 mm dia. VW416B
^ Thrust pad VW447H
^ Assembly tool T10065
Disassembling
- Open hose clamp on shaft and push back boot.
- Pull joint body off drive axle.
- Remove circlip (use commercial-type pliers -1- or VW161A).
- Insert axle shaft in press.
- Press triple roller star off axle shaft.
- Pull joint boot off shaft.
- Clean shaft, joint body and groove for seal.
Assembling
- Push small hose clamp for boot onto shaft.
- Push joint boot onto shaft.
- Push joint body onto shaft.
Installing triple roller star (tapered drive shaft version):
^ Chamfer on star faces toward shaft and is used as an assembly aid.
- Install triple roller star on shaft and press on as far as stop.
Installing triple roller star (cylindrical drive shaft version):
- Install triple roller star on shaft and press on as far as stop.
Both drive shaft versions (continued):
- Make sure pressure does not exceed 3.0t!
- If necessary, coat splines of drive axle and triple roller star with polycarbamide grease G052142A2.
- Install circlip (ensure proper seating).
- Slide joint body over rollers and hold in position.
- Press 70 g of drive axle grease from repair kit into triple roller star.
- Press 60 g of drive shaft grease from repair kit into boot.
- Install joint boot.
- Install hose clip.
Checking outer constant velocity joint
The joint should be disassembled to replace dirty grease or for checking the balls and ball tracks for wear and damage.
Removing
- Before disassembling, mark position of ball hub in relation to ball cage and joint body with an electric scribe or oil stone - arrow -.
- Swing ball hub and ball cage and take out balls one after the other.
- Turn cage until two cage openings - arrow - are level with joint body.
- Lift out cage together with hub.
- Swing one segment of the hub into one of the cage openings.
- Pivot hub out of cage.
Note:
^ The 6 balls in each joint belong to one tolerance group. Check stub axle, hub, cage and balls for pitting and signs of seizure.
^ Excessive backlash in the joint will cause knocking or jolts under load change; in such cases the joint must be replaced.
^ Polished areas and ball track marks are not a reason for changing the joint.
Installing
Installation is performed in reverse sequence; note the following:
- Pack half of the total quantity of grease into the joint body.
- Install cage with hub into joint body.
Note: Cage must be inserted in correct position (i.e. sides facing in same direction as original position).
- Press in the balls one after the other from opposite sides, taking care to re-establish the original position of the hub relative to the cage and the joint body.
- Install new circlip in shaft.
- Distribute remaining grease in boot.