Drive Axle with Triple Roller Joint AAR3300i

Overview - Drive Axle with Triple Roller Joint AAR3300i

1. 1
   Outer CV Joint

   • Replace only as a complete unit.
   • Removing.
   • Installing: Drive onto shaft with plastic hammer until compressed circlip seats.
   • Checking.
2. 2
   Bolt

   • There are different versions.
   • Allocation. Refer to the Parts Catalog.

WARNING

• There are two types of twelve-point bolts, with and without ribs. Distinguishing characteristics. Refer to → Fig. ""Difference between A Twelve-Point Bolt with Ribs and A Twelve-Point Bolt without Ribs""
• When installing a twelve-point bolt, always check what type of twelve-point bolt is to be used.
• Use the correct tightening specification for the specific bolt.
• The tightening specification for a twelve-point bolt "with" ribs is 70 N·m + 90º. Refer to → Chapter "Twelve-Point Bolt with Ribs, Loosening and Tightening, Drive Axle Threaded Connection" for loosening and tightening specifications.
• The tightening specification for a twelve-point bolt "without" ribs is 200 N·m + 180º. Refer to → Chapter "Twelve-Point Bolt without Ribs, Loosening and Tightening, Drive Axle Threaded Connection" for loosening and tightening specifications.

• Always replace if removed

1. 1
   Circlip

   • Always replace if removed
   • Insert in shaft groove
2. 2
   Thrust Ring

   • Installation position.
3. 3
   Plate Spring

   • Installation position.
4. 4
   Clamp

   • Always replace if removed
   • Tensioning.
5. 5
   CV Boot for CV Joint

   • Check for tears and scuffing
   • Material: Hytrel polyelastomer
6. 6
   Clamp

   • Always replace if removed
   • Tensioning.
7. 7
   Driveshaft
8. 8
   Clamp

   • Always replace if removed
   • Tensioning.
9. 9
   CV Boot for Triple Roller Joint

   • Check for tears and scuffing
10. 10
    Clamp

    • Always replace if removed
    • Tensioning.
11. 11
    Triple Roller Star with Rollers

The chamfer -arrow- faces the drive axle splines.

1. 1
   Circlip

   • Always replace if removed
   • Insert in shaft groove
2. 2
   Joint
3. 3
   Circlip

   • Always replace if removed

Difference between A Twelve-Point Bolt with Ribs and A Twelve-Point Bolt without Ribs

The contact surfaces -arrow A- and -arrow B- are different on the two-point bolts.

1. 1
   Twelve-point bolt with ribs -arrow A-
2. 2
   Twelve-point bolt without ribs -arrow B-

   

Drive Axle with Triple Roller Joint AAR3300i, Disassembling and Assembling

Special tools and workshop equipment required

• Press Plate -VW401-
• Press Plate -VW402-
• Press Piece - Rod -VW408A-
• Press Piece - Rod -VW411-
• Press Piece - 37mm -VW416B-
• Press Piece - Multiple Use -VW447H-
• Hose Clip Pliers -VAG1275A-
• Torque Wrench 1331 5-50Nm -VAG1331-
• Torque Wrench 1332 40-200Nm -VAG1332-
• Clamping Pliers -VAG1682A-
• Tripod Joint Tool -T10065-
• Slide Hammer Set -VW771-
• Puller - Driveshaft -T10382-

Removing the Outer CV Joint

• Clamp the drive axle with protective jaws in a vise clamp.
• Fold back boot.
• Align the Puller - Driveshaft -T10382- so that the flat side of the Puller - Driveshaft - Removing Plate -T10382/1- faces the Puller - Driveshaft - Spindles -T10382/2-.
• Attach the Puller - Driveshaft -T10382- to the Slide Hammer Set -VW771-.
• Remove the CV joint from the drive axle using the Puller - Driveshaft -T10382- and Slide Hammer Set -VW771-.

1. 1
   Puller - Driveshaft - Removing Plate -T10382/1-
2. 2
   Puller - Driveshaft - Spindles -T10382/2-

   

Installing the Outer CV Joint

Installed Location: Spring Washer and Thrust Washer on Outer Joint

1. 1
   Plate Spring
2. 2
   Thrust Ring

   

• Install the new circlips.
• Slide the new CV boot onto the drive axle if necessary.
• Use a plastic hammer to install it on the shaft until the locking ring locks secure.

Disassembling

• Open both clamps at inner joint and slide back CV boot.
• Remove joint from drive axle.
• Remove the circlip.

1. Pliers (commercially available)

• Insert the drive axle into the press.

• Press the triple roller star off the axle shaft.
• Pull off CV boot from shaft.
• Clean the shaft, joint and groove for the seal.

Assembling

• Slide small clamp for joint protective boot onto shaft.
• Slide CV boot onto shaft.
• Slide joint piece onto shaft.

Triple Roller Star, Mounting

Conical Drive Axle Version

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 the pressure does not increase above 3.0 t.
• If necessary, coat the splines of the driveshaft and triple roller star with Lubricant -G 052 142 A2-.
• Insert the circlip while making sure it sits properly.
• Press half of the joint grease from the repair set into the triple roller joint.
• Slide joint piece over rollers and secure.
• Press the remaining half of the drive axle grease from the repair kit into the rear side of the triple roller joint.
• Install CV boot.

Triple Roller Star, Mounting

Cylindrical-Type Drive Axle

• Connect triple roller star on shaft and press on up to stop.
• Make sure the pressure does not increase above 3.0 t.
• If necessary, coat the splines of the drive axle and triple roller star with Lubricant -G 052 142 A2-.
• Insert the circlip while making sure it sits properly.
• Press half of the joint grease from the repair set into the triple roller joint.
• Slide joint piece over rollers and secure.
• Press the remaining half of the drive axle grease from the repair kit into the rear side of the triple roller joint.
• Install CV boot.
• Push the protective boot onto the joint and mount the clamp.