Volkswagen Golf Service & Repair Manual: Dismantling and assembling drive shaft, triple roller joint AAR3300i

Special tools and workshop equipment required

Thrust plate -VW 401-

Thrust plate -VW 402-

Press tool -VW 408 A-

Press tool -VW 411-

Tube -VW 416 B-

Thrust washer -VW 447 H-

Hose clip pliers -V.A.G 1275-

Torque wrench -V.A.G 1331-

Torque wrench -V.A.G 1332-

Special pliers -V.A.G 1682-

Assembly tool -T10065-

Multi-purpose tool -VW 771-

Puller -T10382-

Removing outer constant velocity joint

Clamp drive shaft in vice using protective jaw covers.
Fold back boot.
Set puller -T10382- up so that smooth side of puller plate -T10382/1- points to spindles -T10382/2-.
Assemble puller -T10382- complete with multi-purpose tool -VW 771-.

Pull constant velocity joint from drive shaft with puller -T10382- and multi-purpose tool -VW 771-.

1 -	Puller plate -T10382/1-

2 -	Spindles -T10382/2-

Driving on outer constant velocity joint

Install new retaining ring.
If necessary, push new joint boot onto drive shaft.
Knock onto shaft with plastic hammer until circlip engages.

Dismantling triple roller joint

Clamp drive shaft in vice using protective jaw covers.
Unfasten both clamps on inner joint and push back boot.
Pull joint body off drive shaft.

Remove retaining ring.

1 -	Pliers (commercially available)

or -VW 161 A-
Set drive shaft into press.

Press triple roller star off drive shaft.
Pull boot off shaft.
Clean shaft, joint body and groove for seal.

Assembling triple roller joint

Push small hose clip for boot onto shaft.
Push joint boot onto shaft.

Fit triple roller star

Chamfer on triple roller star -arrow- faces towards shaft and serves as an assembly aid.

Fit triple roller star onto shaft and press on to stop.
Ensure that pressure does not exceed 3.0 t.
If necessary, coat splines of drive shafts and triple roller star with lubricating paste -G 052 142 A2-.
Insert retaining ring, ensuring that it is seated correctly.
Press half of total amount of grease from repair kit into triple roller joint.
Place boot adapter onto joint.
Slide joint body over rollers and hold.
Press remaining amount of grease from repair kit into rear of triple roller joint.

Slide boot onto boot adapter and ensure that boot engages correctly in groove -arrow- of adapter.

Install clamp.

Note Clamping lug of clamp -arrow A- must be located between securing flanges of joint body -arrows B-. This is the only way of assuring that the multi-point socket head bolts can be guided correctly when installing the drive shaft.

Tightening clamp on large diameter of inner joint

Position clamp tensioner -V.A.G 1682- as shown in illustration. Ensure jaws of tensioner lie in corners -arrows B- of ear on O-type clip.
Tighten clamp by turning spindle with a torque wrench (do not cant pliers).

Note Due to the hard material of the protective boot (compared to rubber) and the necessity of using a stainless steel clamp, it is only possible to tension the clamp with clamp tensioner -V.A.G 1682-.

Specified torque: 25 N·m.

Use torque wrench -C- with adjustment range 5 … 50 N·m, (e.g. torque wrench -V.A.G 1331-). Make sure thread of spindle -A- on pliers moves freely. Lubricate with MoS2 grease if necessary. If the thread is tight (e.g. due to dirt), the required clamping force for the clamp will not be attained although the specified tightening torque is applied.

Tighten clamp on outer joint

Position clamp tensioner -V.A.G 1682- as shown in diagram. Ensure jaws of tensioner lie in corners -arrows B- of ear on O-type clip.
Tighten clamp by turning spindle with a torque wrench (do not cant pliers).

Dismantling and assembling drive shaft, triple roller joint AAR3300i