Drive Axle With Triple Roller Joint AAR2600i
Drive Axle with 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)
• Sleeve (VW 416 B)
• Thrust pad (VW 447 H)
• Hose clamp pliers (V.A.G 1275)
• Torque wrench (V.A.G 1331)
• Torque wrench (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 Outer Constant Velocity Joint
- Secure drive shaft with protective covers in vise clamp.
- Fold back boot.
- Align the (T10382) so that the flat side of the plate (T10382/1) faces the spindles (T10382/2).
- Attach the (T10382) to the (VW 771).
- Remove the CV joint from the drive axle using the (T10382) and (VW 771).
1. Plate (T10382/1)
2. Spindles (T10382/2)
Driving on Outer CV Joint
Installed Location: Spring Washer and Thrust Washer on Outer Joint
1 - Dished washer
2 - Thrust washer
- Install the new circlips.
- Slide new CV boot onto drive axle if necessary.
- Drive it onto shaft with plastic hammer until securing ring engages.
Disassembling
- Open both clamps at inner joint and slide back CV boot.
- Pull off joint piece from drive axle.
- Remove securing ring.
1 Pliers (commercially available)
- Insert drive axle in vise.
- Press triple roller star off drive axle.
- Pull off CV boot from shaft.
- Clean shaft, joint and groove for oil seal.
Assembling
- Slide small clamp for joint protective boot onto shaft.
- Slide CV boot onto shaft.
- Slide joint piece onto shaft.
Mount Triple Roller Star
Conical-Type Drive Axle
The chamfer on star faces toward shaft, this is used as an assembly aid.
- Connect triple roller star on shaft and press on up to stop.
- Make sure that pressure does not increase above 3.0 t!
- If necessary coat drive axle splines and triple-roller star with lubricating paste (G 052 142 A2).
- Insert securing ring, be sure to fit properly.
As of 08.2004, a different grease will be used for triple roller joints. The grease must not be mixed with grease previously used. Therefore, triple roller joint must be cleaned before greasing when performing service work.
- Press 70 grams of joint grease from repair set, into triple roller joint.
- Slide joint piece over rollers and secure.
- Press 60 grams of joint grease, from repair set, into the reverse side of the triple roller joint.
- Install CV boot.
Mount Triple Roller Star
Cylindrical-Type Drive Axle
- Connect triple roller star on shaft and press on up to stop.
- Make sure that pressure does not increase above 3.0 t!
- If necessary coat drive axle splines and triple-roller star with lubricating paste (G 052 142 A2).
- Insert securing ring, be sure to fit properly.
- Press 70 grams of joint grease from repair set, into triple roller joint.
- Slide joint piece over rollers and secure.
- Press 60 grams of joint grease, from repair set, into the reverse side of the triple roller joint.
- Install CV boot.
- Tension both clamps using (V.A.G 1275).