Triple-Rotor Joint AAR 2900, Disassembling and Assembling

Triple-rotor joint AAR 2900, disassembling and assembling

Disassembling
- Open clamp on joint and slide back protective boot.
- 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 part - 1 to 3 -.

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

If parts are not marked when assembling, the components are not brought back to their original installation position. It is then 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 roller joint housing
2 - Triple roller star
3 - Axle shaft

- Hold joint and take axle shaft out of vice.
Make sure that the rollers do not slide off triple roller star and fall on 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.
- Remove 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 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.
- Make sure that the pressure does not exceed 3.0 t!
- If necessary coat axle 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.
- Press 70 grams of joint grease, from repair kit, into triple roller joint.
- Press 70 grams of joint grease, from repair kit, into reverse side of 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 housing

- Insert axle shaft in press.

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

The circlip must be audibly engaged when it seats!
- Install joint protective boot.

- Position triple roller joint approximately in middle of sliding part. See distance between minimum and maximum
- Hold triple roller joint in this position and lift boot slightly - arrow -.

- Install clamp.
This allows a possible vacuum inside the boot to escape.

Note:
^ For a better alignment of the multi-point socket head bolts when mounting the axle shaft, it is necessary that the clamping ear of the clamp - arrow A - is placed between fixing flanges from joint - arrow B -.

- Tighten clamp with hose clamp pliers V.A.G. 1275.