Triple-Rotor Joint AAR 2900, Disassembling and Assembling

Triple-rotor joint AAR 2900, disassembling and assembling
Disassembling

- Open clamp on joint and slide back protective boot

- 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 -13 - .
- It is only necessary to mark parts when the rollers are pulled off the triple roller star.
- 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 - Triple joint housing
2 - Triple roller star
3 - Axle 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 axle 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.

- Take off rollers -1 - and place on a clean surface.
- Remove circlip.
- Pliers (commercially available)

- Insert axle shaft in press.
- Hold axle shaft, then press triple roller star off axle 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 triple roller star
The chamfer on tripod star faces toward shaft, this is used as an assembly aid.
- Install triple roller star onto shaft and press onto stop.
- Make sure that the pressure does not exceed 3.0 t (6614 lb)!
- If necessary coat axle shaft splines and triple-roller star with lubricating paste G 052142A2.
- Insert circlip, make sure seated correctly.
- Install rollers onto triple roller star as per markings.
- Slide joint over rollers and hold.
- Press 70 grams (2.5 oz.) of joint grease, from repair set, into triple roller joint.
- Press 70 grams (2.5 oz.) of joint grease, from repair kit, 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 - O-ring
4 - Tripod joint

- Insert axle shaft in press.
- Press cover - 1 - into triple roller joint until circlip can be installed.
- Insert circlip, make sure seated correctly.
- The circlip must be heard when it seats!

- 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 -.
- Install hose clamp.
- This allows a possible vacuum inside the boot to escape.

Note: For a better alignment of the multi-point socket head bolts when mounting the axle shaft, it is necessary that the clamping ear of the clamp - arrow A - is placed between the fixing flanges from the joint -arrow B - .

- Tighten clamp with hose clamp pliers V.A.G. 1275 .