Audi Workshop Service and Repair Manuals

Grease fill of joints

Note:

Re-grease joint on replacing boot.

Exploded view of components

• Twelve-point nut
• ◆ Self-locking
• ◆ Always replace after removing
• ◆ Unfastening and tightening
  
• ◆ Remove any paint remnants and/or corrosion in thread of outer joint before screwing on nut
• Boot for constant velocity joint
• ◆ Check for cracks and abrasion
• Clamp
• ◆ Replace
• ◆ Tensioning => Fig.5
• Drive shaft
• Clamp
• ◆ Replace
• ◆ Tensioning => Fig.5

• Joint element
• Multi-point socket-head bolt
• ◆ Pre-tightening torque: 10 Nm
• ◆ Tightening torque for M8: 40 Nm
• ◆ Tightening torque for M10: 70 Nm
• Rollers
• Triple roller star
• ◆ Chamfer -arrow- faces drive shaft splines
• Circlip
• ◆ Replace
• O-ring
• ◆ Replace with plain sealing ring -Item 12- when performing repair work
• Plain sealing ring
• ◆ Part of repair set
• Cap
• ◆ Replace

• Clamp
• ◆ Replace
• ◆ Tensioning => Fig.4
• Boot for triple roller joint
• Clamp
• ◆ Replace
• ◆ Tensioning => Fig.6
• Dished washer
• ◆ Installation position => Fig.2
• Spacer ring (plastic)
• ◆ Installation position => Fig.2
• Circlip
• ◆ Replace
• ◆ Insert in shaft groove
• Outer constant velocity joint
• ◆ Replace only as complete assembly
• ◆ Checking
• ◆ Removing => Fig.1
• ◆ Greasing =>Table, Page 40-183
• ◆ Installing:
• ‒ Use plastic-headed hammer to drive joint onto shaft until circlip engages

→ Fig.1    Removing outer constant velocity joint

• ‒ Tap firmly with light alloy hammer to drive constant velocity joint off drive shaft.

Fig.2    → Installation position of spacer ring and dished washer

•     1 -    Dished washer
•     2 -    Spacer ring (plastic)

→ Fig.3    Venting rubber boot

Boot is often squashed on positioning it on joint housing. This produces a vacuum in the boot, which causes a fold to form whilst driving -arrow-.

Attention is therefore to be paid to the following:

• ‒ Before tensioning clamps, lift boot to ensure pressure equalisation.

→ Fig.4    Tensioning large clamp for rubber boot

→ Fig.5    Tensioning stainless-steel clamps for Hytrel boots

• ‒ Apply pliers V. A.G 1682 as shown. Make sure jaws of pliers make contact with corners (arrows B) of hose clamp.
• ‒ Tension hose clamp by turning spindle -A- with torque wrench (take care not to tilt pliers).
• ‒ Tightening torque: 20 Nm

Notes:

• ◆ Make sure thread of spindle on pliers moves freely. Lubricate with MoS2 grease if necessary.
• ◆ If stiff, e.g. due to dirt on thread, required clamp tensioning force will not be attained with specified tightening torque.

→ Fig.6    Tensioning small clamp for rubber boot

Dismantling and assembling triple roller joint AAR 2900

Special tools and workshop equipment required

• ◆ Thrust plate VW 401
• ◆ Thrust plate VW 402
• ◆ Press tool VW 408 A
• ◆ Press tool VW 411
• ◆ Tubular section VW 416 B
• ◆ Thrust pad VW 447 H

• ◆ Press tool VW 412
• ◆ Thrust pad 2050
• ◆ Workshop press V.A.G 1290 A
• ◆ Assembly device T10065

Dismantling

• ‒ Unfasten clamp at shaft and push back boot.
• ‒ → Drive slotted screwdriver or the like into cap and prise off cap.

• ‒ → Mark installation position of components -1. . .3- using waterproof felt-tip pen.

•     1 -    Joint element
•     2 -    Triple roller star
•     3 -    Drive shaft

Notes:

• ◆ Marking is only necessary if rollers can be detached from triple roller star.
• ◆ Noise may subsequently be encountered whilst driving if components are not fitted in their original position on assembly.

• ‒ Take rubber ring -arrow- out of groove.

• ‒ Grasp hold of joint element and take drive shaft out of vice.

Note:

Make sure rollers do not slide off triple roller star and drop onto ground.

• ‒ Hold drive shaft with joint element in vertical position and then use other hand to slowly push back joint element.

• ‒ → Use felt-tip pen to mark installation position of rollers -1- with respect to triple roller star -2-.
• ‒ Detach rollers and set down on clean surface.

• ‒ → Remove circlip.

•     1 -    Pliers (commercially available)
• or VW 161 A

• ‒ Insert drive shaft in press.
• ‒ → Grasp hold of drive shaft and then press triple roller star off drive shaft.
• ‒ Detach joint element with boot from shaft.
• ‒ Clean shaft, joint element and groove for sealing ring.

Assembling

• ‒ Slip small clamp for boot onto shaft.
• ‒ Slip boot onto shaft.
• ‒ Slip joint element onto shaft.

Fitting triple roller star

• ‒ Chamfer at star faces shaft and is used as an assembly aid
• → Attach triple roller star to shaft and press home.

• Make sure pressure does not exceed 3.0 t!

• ‒ If necessary, coat splines of drive shaft and triple roller star with polycarbamide grease G 052 142 A2.
• ‒ Fit circlip, making sure that it is correctly positioned.
• ‒ Attach rollers to triple roller star in line with marks.
• ‒ Slip joint element over rollers and hold in position.

• ‒ Press 70 g of drive shaft grease from repair set into triple roller joint.
• ‒ Press 70 g of drive shaft grease from repair set into boot.
• ‒ Slip joint element over rollers and hold in position.

• ‒ → Insert plain ring -3- from repair set in groove of triple roller joint -4-.

•     1 -    Circlip
•     2 -    Cap from repair set

• ‒ Insert drive shaft in press.

• ‒ → Press cap -1- into triple roller joint such that circlip can be inserted.
• ‒ Fit circlip, making sure that it is correctly positioned.
• ‒ Circlip must be heard to engage

• ‒ Fit boot.
• ‒ → Position triple roller joint roughly in centre of adjustment range (refer to distance between min. and max.).
• ‒ Hold triple roller joint in this position and lift boot -arrow-.
• ‒ Any vacuum within boot can thus be dissipated
• ‒ Fit clamp.

Checking outer constant velocity joint

The joint must be dismantled for replacing grease in the event of severe contamination or if ball contact surfaces are to be checked for wear and damage.

Removing

• ‒ → Use electric scriber or whetstone to mark position of ball hub with respect to ball cage and housing before dismantling -arrow-.
• ‒ Swivel ball hub and ball cage and take out balls one after the other.

• ‒ → Turn cage until two cage openings (arrow) are in contact with joint housing.
• ‒ Lift out cage with hub.

• ‒ → Swivel one hub segment into cage opening.
• ‒ Tip hub out of cage.

Notes:

• ◆ The 6 balls for each joint are of one tolerance group. Check stub axle, hub, cage and balls for pitting and signs of seizure.
• ◆ Excessive backlash in joint becomes apparent from load change jolts; joint is then to be replaced.
• ◆ Smooth areas and running marks on balls do not necessitate joint replacement.

Installing

Install in reverse order, paying attention to the following:

• ‒ Press half the total quantity of grease into the joint housing.
• ‒ Insert cage with hub in joint housing.

Note:

Cage must be inserted in correct position.

• ‒ Consecutively press in opposite balls, taking care to re-establish previous position of ball hub with respect to ball cage and joint housing.
• ‒ Insert new circlip in shaft.
• ‒ Distribute remaining grease in boot.