Audi Workshop Service and Repair Manuals

Dismantling and assembling triple roller joint AAR 2900

Special tools and workshop equipment required

t	Tube -VW 416 B-

t	Press tool -VW 412-

t	Tube -VW 426-

t	Tube -3110-

t	Puller -Kukko 12/1-

t	Thrust piece -2050-

t	Pliers -V.A.G 1275-

t	Circlip pliers -VW 161 A-

t	Spindle -3207-

Dismantling –  Knock out cover.   Note t  Use the old bolt when knocking out. t  When doing so hold the shaft at an angle of approx. 20°. Use a plastic-headed hammer and tube -3110-.

–  Remove any swarf in area around cover. –  Release the large hose clip. –  Release small hose clip on shaft and push back boot.

–  Mark installation position of components -1- to -3-. The joint may be noisy if these parts are not marked and reinstalled in their original positions. Use a waterproof felt-tip pen for marking. –  Take O-ring -arrow- out of groove. 1 -  Joint body 2 -  Triple roller spider 3 -  Drive shaft

–  Remove circlip. 1 -  Pliers (commercial type)

–  Detach triple roller spider from drive shaft. To do so, use puller -Kukko 12/1- (commercially available). –  Remove grease from groove for O-ring. –  Check rollers and roller races for wear. –  Clean shaft and housing. Assembling –  Push small hose clip for boot onto shaft. –  Push new boot onto shaft. –  Push joint body onto shaft. –  Push boot onto joint body.

Fitting triple roller spider –  Grease splines -A- on drive shaft lightly with grease used in joint before fitting joint or triple roller spider onto drive shaft.

The chamfer -arrow- on the spider faces the shaft and facilitates assembly. –  Fit triple roller spider onto shaft according to markings and drive home onto stop. –  Install circlip (ensure proper seating). –  Press 70 g of grease -G 000 605- from repair kit into triple roller joint. –  Push joint body over rollers.   Note Take care not to twist the boot when doing so. –  Press 70 g of grease -G 000 605- from repair kit into back of triple roller joint.

–  Carefully clean groove -4- for O-ring. –  Insert O-ring -3- in groove -4-. For ease of illustration, components are shown removed. 1 -  Circlip 2 -  Cover from repair kit 3 -  O-ring 4 -  Groove in triple roller joint

–  Insert drive shaft in press. –  Lightly press on cover -1- from repair kit so you can then fit circlip from repair kit. –  Insert circlip from repair kit so it fits all round under retaining lip.   Note Make sure that circlip engages audibly.

–  Position joint body in central position. The correct position is between “min” and “max” in the illustration.   Note When setting the joint body to the central position, use a screwdriver -arrow- or similar to let air into the boot.

–  Fit the hose clip -2-.   Note To facilitate fitting of multi-point socket-head bolts when installing drive shaft, lug -2- on hose clip must be positioned between mounting flanges -1- on joint body.

Tightening hose clip on inner joint

–  Use pliers -V.A.G 1275- to tighten small hose clip.