Drive Axle, Triple Roller Joint AAR2600i

Drive Axle, Triple Roller Joint AAR2600i

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 408 A)

• Punch (VW 411)

• Tube 37 mm Dia. (VW 416 B)

• Thrust Pad (VW 447 H)

• Hose Clamp Pliers (V.A.G 1275)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• CV Joint Boot Clamp Tool (V.A.G 1682)

• Assembly Tool (T10065)

• Slide Hammer - Complete Set (VW 771)

• Puller (T10382)

Removing the Outer Constant Velocity (CV) Joint

- Secure the drive axle with protective covers, in a vise.

- Fold back the CV joint boot.

- Align the puller (T10382) so that the flat side of the plate (T10382/1) faces the spindles (T10382/2).

- Attach the puller (T10382) to the slide hammer (VW 771/1/1).

- Remove the CV joint from the axle shaft using the puller (T10382) and slide hammer (VW 771/1/1).






1. Plate (T10382/1)

2. Spindles (T10382/2)


Installing the Outer CV Joint

Installed Position: Concave Washer and Thrust Ring on the Outer CV joint





1 - Concave washer

2 - Thrust ring

- Install the new circlips.

- Slide the new CV joint boot onto the axle shaft, as necessary.

- Use a plastic hammer to install it on the shaft until the circlip locks secure.

Disassembling

- Open both clamps at the inner CV joint and slide back the CV joint boot.

- Remove the CV joint from the axle shaft.

- Remove the lock ring.






1 Pliers (commercially available)

- Insert the axle shaft in a vise.

- Press the triple roller star off the axle shaft.






- Pull off the CV boot from the axle shaft.

- Clean the axle shaft, CV joint and groove for the oil seal.

Assembling

- Slide the small clamp for the CV joint boot onto the shaft.

- Slide The CV joint boot onto the shaft.

- Slide the joint piece onto the shaft.

Mount the Triple Roller Star

Conical Type Drive Axle

The chamfer on triple roller star faces toward the axle shaft, this is used as an assembly aid.

- Connect the triple roller star on the shaft and press on up to the stop.






- Make sure that the pressure does not increase above 3.0 t!

- If necessary coat the axle shaft splines and triple-roller star with poly lubricant (G 052 142 A2).

- Insert the lock ring, be sure to fit properly.

As of August.2004, a different grease will be used for the triple roller joints. The grease must not be mixed with the old grease previously used. Therefore, the triple roller joint must be cleaned before greasing when performing service work.

- Press 70 grams of the joint grease from the repair kit, into the triple roller joint.

- Slide the joint piece over the rollers and secure it.

- Press 60 grams of the joint grease, from the repair kit, into the reverse side of the triple roller joint.

- Install the CV joint boot.

Mounting the Triple Roller Star

Cylindrical Type Drive Axle

- Install the triple roller star on the shaft and press on up to the stop.






- Make sure that the pressure does not increase above 3.0 t!

- If necessary coat the drive axle splines and triple roller star with poly lubricant (G 052 142 A2).

- Insert the lock ring, be sure to fit properly.

- Press 70 grams of the joint grease from the repair kit, into the triple roller joint.

- Slide the joint piece over the rollers and secure.

- Press 60 grams of the joint grease from the repair kit, into the reverse side of the triple roller joint.

- Install the CV boot.

- Tension both clamps using the hose clamp pliers (V.A.G 1275).