Triple-Roller Joint AAR 2900, Disassembling and Assembling

Triple-rotor joint AAR 2900, disassembling and assembling
Disassembling





- Open hose clamp.
- Open clamp on shaft and slide protective boot back.





- Place screwdriver or similar into cover and pry off cover.

If the cover cannot be pried off, we recommend that a screwdriver is placed in again on the opposite side, then pry off cover.





- Mark installation position of parts 1 . . . 3.

It is only necessary to mark parts when the rollers are pulled off the star.

If the parts are not marked and 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. Triple joint housing
2. Triple roller star
3. Axle shaft

- Hold joint and remove axle shaft out of vice.

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.

- Take off rollers -1- and place on a clean surface.





- Remove circlip.

1. Pliers VW 161A or available commercially
- Place 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 star

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





- Install star onto shaft and press in to stop.
- Make sure that the pressure does not exceed 3.0 t (6614 lbs.)!
- If necessary coat axle shaft splines and star with lubricating paste G 052 142 A2.
- Insert circlip, make sure that it seats correctly.
- Install rollers on star as per markings.
- Slide joint over rollers and hold.

- Press 70 grams (2.5 oz.) of joint grease, from repair set, into triple roller joint.

- Press 70 grams (2.5 oz.) of joint grease, from repair set, into the reverse side of the triple roller joint and protective boots.





- Place seal -3- from repair kit in the groove -4- of triple roller joint.

1. Circlip
2. Cover from repair kit
3. Seal
4. Triple roller joint

- Insert axle shaft in press.





- Press the cover -1- into triple roller joint until the circlip can be installed.
- Insert circlip, make sure seated correctly.

The circlip must be heard when it seats!

- Install joint protective boots.





- 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 hose clamp.





- Tighten small hose clamp with pliers VAG 1275.