Constant Velocity Joint: Service and Repair

Triple roller joint, disassembling and assembling
Vehicles with manual transmission
Servicing the triple roller joint is only possible on drive shafts installed in vehicles with manual transmissions.

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





- Drive screwdriver or similar into cover and pry off cover.
If the cover cannot be pried off, we recommend that a screwdriver is driven in on the opposite side, then pry off cover.





- Mark installation position of parts 1 through 3.
If the parts are not marked when assembling, the components are not brought back to their previous installation position then it is possible that it will be noisy when driving.
A waterproof felt tipped pen is suitable for marking.
- Take rubber ring -arrow- out of groove.
1. Joint
2. Triple roller star
3. Drive shaft
- Hold joint and take drive shaft out of vice.
Make sure that the rollers do not slide off the triple roller star and fall on the ground!
- Hold drive shaft and joint horizontal and using the other hand slowly slide joint back.





- Mark installation position of rollers -1- to triple roller star -2- using a felt tipped pen.
It is only necessary to mark parts when the rollers are pulled off the spider.
- Take off rollers -1- and place on a clean surface.





- Remove circlip.
1. Pliers (commercial type)
- Insert drive shaft in press.





- Hold drive shaft, then press triple roller star off drive shaft.
- Pull joint with joint protective boot off shaft.
- Clean shaft, joint and groove for oil seal.

Assembling
- Slide small clamp for joint protective boot onto shaft.
- Slide joint protective boot onto shaft.
- Slide joint onto shaft.

Assembling spider
The chamfer on spider faces toward shaft, this is used as an assembly aid.





- Install spider onto shaft and press onto stop.
The diagram shows a conical shaft in the area of the support -arrow-.
- Press tripod star on drive shaft with cylindrical shaft





This step applies only to drive shafts, which remain cylindrical at the end -arrow-.

CAUTION:
^ Make sure that the pressure does not exceed 3.0 t!
^ If necessary coat drive shaft splines and tripod star with lubricating paste G 052 142 A2.

- Insert circlip, make sure seated correctly.
- Install rollers onto spider as per markings.
- Slide joint over rollers and hold.
- Press 70 grams of joint grease, from repair set, into triple roller joint.
- Press 70 grams of joint grease, from repair set, into the reverse side of the triple roller joint and protective boot.





- Place seal -3- from repair kit in groove -4- of triple roller joint.
1. Circlip
2. Cover from repair kit
3. Seal
4. Triple roller joint
- Insert drive shaft in press.





- Press cover -1- into triple roller joint until circlip can be installed.
- Insert circlip, make sure seated correctly.

Note: The circlip must be audibly engaged to locate!

- Install joint protective boot.





- Position the triple roller joint approximately in the middle of the sliding part. See distance between min. and max.
- Hold triple roller joint in this position and lift the boot slightly -arrow-.
This allows a possible vacuum inside the boot to escape.





- Tighten small hose clamp with pliers VAG 1275.