Triple-Roller Joint AAR 2000, Disassembling and Assembling

Triple-roller joint AAR 2000, disassembling and assembling

Special tools and equipment
^ VW 426 Tube
^ 40-204 A Tightener
^ 3340 Pliers

Disassembling

- Open hose clamp.
- Open clamp on axle shaft and slide back triple-rotor joint boot.

- Open plate tabs with a screwdriver and pry cover.

- Mark installation position of parts 1 to 3.

Notes:
^ If parts are not marked, and the components are not assemble to their previous position. It is possible it will be noisy when driving.
^ Use a waterproof felt tipped pen marking parts.

1. Triple rotor joint housing
2. Triple-rotor star
3. Axle shaft

- Remove O-ring -arrow- from groove.
- Hold joint and take axle shaft out of vise.

CAUTION:

Make sure that the rollers do not slide off the triple-rotor star and fall off.

- Remove circlip.

1. Pliers VW 161 A or (commercial type)

- Install axle shaft in press.

- Hold axle shaft, press triple-rotor star off axle shaft.
- Remove triple-rotor star with rollers and place them on a clean surface.
- Pull joint off shaft.
- Pull boot off shaft.
- Clean shaft and housing.

Assembling

- Slide triple-rotor joint boot onto shaft.
- Slide triple-rotor joint housing onto shaft.

Assembling triple-rotor star

The chamfer star faces toward shaft. This is used as an assembly aid.

- Install triple-rotor star onto shaft per markings and press onto stop.
- Install circlip, make sure it is seated correctly.
- Press 60 grams (2.12 oz.) of joint grease from repair kit into triple roller joint.
- Slide joint over rollers and hold.
- Press 60 grams (2.12 oz.) of joint grease from repair kit into the reverse side of the triple roller joint.
- Install joint boot.
The ridge in the joint boot must seat in the joint groove.
- Remove axle shaft from vise and re-clamp triple-rotor joint housing in vise.

- Install new seal -arrow- from repair kit into groove.
- Install new cover to joint housing.
The holes of the cover and joint housing must align.

- Install hose clamp.