Triple-Roller Joint, Disassembling and Assembling

Triple-Roller Joint, Disassembling and Assembling

Disassembling
^ Knockout cover

Note:
^ Use old bolt when knocking out
^ Hold shaft at approximately 20° angle during this

Use plastic hammer and 3110 special tool.





^ Remove any shavings in area of cover
^ Open large clamp.
^ Open small clamp on shaft and slide back joint protective boot.





^ Mark installation position of parts -1. through -3-.
If the parts are not marked and when assembling, the components are not brought back to their previous installation position and it is possible that it will be noisy when driving.
A waterproof felt tipped pen is suitable for marking.
^ Take round seal -arrow- out of groove.
1 Joint
2 Triple-roller star
3 Drive axle





^ Remove circlip.
1 Pliers (commercial type)





^ Remove triple-roller star from drive axle
Use Kukko 12-1 (arrow) removal tool (commercially available)
^ Remove grease in groove for sealing ring and at splines of shaft
^ Check roller body and track for wear
^ Clean shaft and housing.

Assembling
^ Slide small clamp for joint protective boot onto shaft.
^ Slide new joint protective boot onto shaft.
^ Slide joint onto shaft.
^ Slide joint protective boot onto joint piece.

Assembling triple-roller star
The chamfer -arrow- on star faces toward shaft, this is used as an assembly aid.





^ Install triple-roller star onto shaft as per markings and drive onto stop.
^ Insert circlip, make sure it is seated correctly.
^ Press 70 grams of G 000 605 joint grease from repair set into triple-roller joint.
^ Slide joint piece over rollers.

Note: Be sure that joint protective boot does not get damaged.

^ Press 70 grams of G 000 605 joint grease from repair set into the reverse side of the triple-roller joint.
^ Carefully clean groove for seal.
^ Insert seal into groove.





For the sake of illustration, individual parts are shown removed.
1 - Circlip
2 - Cover from repair set
3 - Sealing ring
4 - Triple-roller joint





^ Insert drive axle in press.
^ Lightly press in cover -1- from repair set, so that the circlip from repair set can be inserted.
^ Insert circlip from repair set all the way around engagement edge.

Note: Be sure circlip engages audibly.





^ Position joint piece in center position.
See min - max position

Note: While joint piece is being positioned in the center position, it is necessary to vent the protective joint boot using, for example, a screwdriver (arrow).





^ Install hose clamp, Refer to Drive axle with triple-roller joint, repairing, See Fig. 1.

Note: The fastening tab -2- of the clamp must be located between the mounting flanges 4 - of the joint piece so that the socket head bolts can be threaded more easily when installing the drive axle.





^ Tighten small hose clamp with pliers VAG 1275.