Triple Roller Joint, Disassembling and Assembling
Triple roller joint, disassembling and assembling
As of 08.2004, a different grease has been introduced for the triple roller joint. This grease is not compatible with that which was previously used. Therefore, the triple roller joint must be cleaned of all grease when servicing.
Vehicles with manual transmission
Servicing the triple roller joint is only possible on axle 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 to 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 piece
2. Triple roller star
3. Axle shaft
^ Hold joint and take axle shaft out of vise.
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.
It is only necessary to mark parts when the rollers are pulled off the triple roller star.
^ Take off rollers - 1 - and place on a clean surface.
^ Remove circlip.
1. 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 triple roller star faces toward shaft, this is used as an assembly aid.
^ Install triple roller star onto shaft and press onto stop.
The diagram shows a conical shaft in the area of the support - arrow -.
Press triple roller star on axle shaft with cylindrical shaft
This step applies only to axle 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 triple-roller star with lubricating paste G 052 142 A2.
^ Insert circlip, make sure seated correctly.
^ Install rollers onto triple roller star as per markings.
^ Slide joint over rollers and hold.
As of 08.2004, a different grease has been introduced for the triple roller joint. This grease is not compatible with that which was previously used. Therefore, the triple roller joint must be cleaned of all grease when servicing.
^ Press 70 grams of joint grease, from repair kit, into triple roller joint.
^ Press 70 grams 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. Triple roller 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 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 using hose clamp pliers V.A.G 1275.