Drive Axle, With Triple Roller Joint AAR 2600i and AAR 3300i With Inner Splines

Drive Axle, with Triple Roller Joint AAR 2600i and AAR 3300i with Inner Splines

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.

- Pull off joint piece from 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.

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

Triple Roller Star, Conical Drive Axle, Installing






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

- Install the triple roller star all the way onto the shaft.

Triple Roller Star, Cylindrical Drive Axle, Installing






- Install the triple roller star all the way onto the shaft.

Continuation for both Drive Axles

- 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

Installation is the reverse of removal, with special attention to the following:

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

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

• 98 mm diameter outer joint, grease quantities => [ Filling the Joints with Grease ] 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 axle.

- Distribute remaining grease in the joint boot.