Triple Roller Joint AAR 2900, Disassembling and Assembling

Triple Roller Joint AAR 2900, Disassembling and Assembling

Special tools, testers and auxiliary items required

• Sleeve (VW 416 B)

• Punch (VW 412)

• Sleeve (VW 426)

• Sleeve (3110)

• Puller (Kukko 12/1)

• Press Piece (2050)

• CV Joint Boot Clamp Tool (V.A.G 1275)

• Circlip Pliers (VW 161 A)

• Pressure Spindle (3207)

Disassembling

- Knock out cap.

• Use old bolt to knock out.

• Hold shaft at approximately 20° for this.

Use plastic hammer and Press Support (3110).





- Remove any shavings in area of cover.

- Open the large clamping sleeve.

- Open the small clamping sleeve on the shaft and slide the protective joint boot back.

- Mark installation position of parts - 1 - to - 3 - with lines.





If they are not marked and are not re-installed in their previously installed positions, noises may occur later during driving operation.

A water-proof felt pen is well-suited for marking.

- Remove round seal - arrow - from groove.

1 Joint piece
2 Triple roller star
3 Drive axle

- Remove securing ring.





1 Pliers (commercially available)

- Pull triple roller star off drive axle. For this, use Puller (Kukko 12/1) (commercially available).





- Remove grease in groove for sealing ring.

- Check roller body and ball cage for wear.

- Clean shaft and housing.

Assembling

- Slide small clamp for joint protective boot onto shaft.

- Slide protective joint boot onto the shaft.

- Slide joint piece onto shaft.

- Slide the protective boot onto the joint.

Mounting triple roller star





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

Chamfer - arrow - on star faces toward shaft, it facilitates assembly.





- Place triple roller star on shaft according to marking and drive on until impact.

- Insert securing ring, be sure to fit properly.

- Press 70 grams of Grease (G 000 605 ) from repair kit into triple roller joint.

- Slide joint over the rollers.

• Make sure CV boot does not get twisted during this.

- Press 70 grams of Grease (G 000 605 ) from repair kit into rear side of triple roller joint.

- Thoroughly clean groove - 4 - for sealing ring.





- Insert O-ring - 3 - in groove - 4 -.

The individual parts are shown disassembled for the sake of a better illustration.

1 Securing ring
2 Cover from repair kit
3 Sealing ring
4 Groove in triple roller joint

- Insert axle shaft in vise.





- Lightly press on cover - 1 - from repair kit so that circlip from the repair kit can be inserted.

- Insert circlip from repair kit all around below engaging groove.

• Make sure circlip engages audibly.

- Position joint in center position. See "min" - " max" position.





• It is necessary to vent CV boot - arrow -, e.g. using a screwdriver, while positioning joint piece in center position.

- Install clamp - 2 -.





• For a better alignment of multi-point socket head bolts when installing drive axle, clamping sleeve connecting tube - 2 - must be between joint connecting flanges - 1 -.

Tightening clamp on inner joint





- Tension small clamp using Pliers (V.A.G 1275 ).