Triple-Rotor Joint, Disassembling and Assembling

Special tools and equipment
- VW 426 Tube
- 40-204A Block
- 3340 Pliers
- VW 161A

Triple-rotor joint, disassembling and assembling
Disassembling





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





- Place screwdriver or similar under cover clip and pry off cover.





- Mark installation position of parts 1, 2 and 3.

NOTE:
- Noises while driving may result if indicated parts are not reassembled to their prior positions.
- Felt tipped pen is suitable for marking.

- Take rubber ring (arrow) out of groove.
1. Triple rotor joint housing
2. Triple roller star
3. Axle shaft
- Hold joint and remove axle shaft from vice





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





- Hold axle shaft, press triple roller star off shaft.
- Remove triple roller star with roller and place on clean surface.
- Remove CV joint from axle shaft.
- Remove sleeve from axle shaft.
- Clean shaft and CV joint.

Assembling
- Slide small clamp and boot for CV joint on shaft.
- Slide CV joint on shaft.

Assembling triple roller star





- Install triple roller star, (chamfer on star faces shaft)..
- Press star in to stop.
- Install lock ring, and ensure lock ring clicks into groove.
- Press in 60 grams (2.1 ounces) of grease G 000 633 (from repair set) into triple roller star.
- Slide CV joint over roller and hold.
- Press in 60 grams (2.1 ounces) of grease G 000 633 (from repair set) into back side of triple roller star.
- Slide CV joint boot in place, bead in boot must lock into groove of CV joint.





- Install new O-ring (arrow), from repair set, in groove.
- Remove axle shaft from vice.

NOTE: Holes from CV boot and joint must align.





- Install boot clamp.





- Tighten small hose clamp with pliers VAG1275.





NOTE:
- To prevent triple rotor joint from being pushed back unintentionally when installing axle shaft, secure triple rotor joint with adhesive tape.
- Remove adhesive tape just before bolting to axle flange.