Constant Velocity (CV) Joint and Triple Roller Drive Axles AAR 2000 and AAR 2900, Removing and Installing

Constant Velocity (CV) joint and triple roller drive axles AAR 2000 and AAR 2900, removing and installing

Special tools, testers and auxiliary items required:

- Hub puller 3283
- Torque wrench V.A.G 1331
- Torque wrench V.A.G 1756

Removing
Wheel bearing must not be burdened while 12-point nut is loose.

If wheel bearing is burdened by weight of vehicle, wheel bearing will be pre-damaged. This will diminish wheel bearing service life.

If it should be necessary to move a vehicle whose drive axle has been removed, before doing so install an outer joint in place of the drive axle and tighten it to 50 Nm, or else wheel bearing will be damaged.
- Lift vehicle enough that the front axle is no longer burdened.
- Remove 12-point nut.
- Raise vehicle.
- Remove wheel.





- Remove sound insulation pan - arrows -.





- Remove left sound insulation - arrows -.

Vehicles with TDI engine
- Remove charge air pipe between charge air cooler and turbocharger.

Continued for all vehicles
- Remove right sound insulation panel.
- Remove drive axle from flange shaft/transmission.





- Mark installation position of bolts - arrows - for ball joint - 1 - on control arm - 2 -.
- Mark installation position of ball joint - 1 - to control arm - 2 -.





- Press out drive axle.

Note: Be sure there is sufficient room when pressing drive axle out.

- Remove drive axle.

Drive axle must not hang down! Otherwise inner joint is damaged by excessive bending.

This work step applies only to vehicles with automatic transmission





- Remove bolts - arrows -.





- Press engine/transmission subframe forward e.g. using a tire iron.
- Now drive axle can be removed.
(- Arrow - points in direction of travel)

Installing
Remove any paint residue and/or corrosion in threads/splines of outer joint.
- Before installing drive axle, coat;
- Splines of outer joint,
- Thread of outer joint,
- Spines of wheel hub,
- Assembly surfaces and thread of 12-point nut with oil.
- Insert drive axle.
- Insert outer joint as far as possible into wheel hub splines.
- Tighten bolts for control arm and ball joint on to old marks.
- Ball joint to control arm: Tightening torque Front axle, tightening torques.
- Pull outer joint into wheel hub until outer joint arrives at installation position in wheel bearing.
- Place drive axle inner joint in position and pre-tighten bolts diagonally to 40 Nm.

Tightening torques
- Screw pendulum support to subframe and tighten to tightening torque.





- Tighten 12-point nut to 200 Nm and release a half a rotation.
- Rotate wheel hub 180°.
- Then rotate further to 50 Nm plus an additional 60°

Note: Torque wrench V.A.G 1756 is recommended for tightening 12-point nut.

- If torque wrench is not available, 12-point nut can be tightened as follows.
- Lower vehicle until wheels touch the ground.
- Tighten 12-point nut to 200 Nm and release a half a rotation.
- Tighten twelve-sided nut to 50 Nm.





- Mark one side of 12-point nut with a line - arrow A -.
- Draw a second line - arrow B - on edge of wheel hub above next indentation.
- Turn 12-point nut until lines match up.