Audi Workshop Service and Repair Manuals

Dismantling and assembling peened triple roller joint AAR 2600 i or 3300 i

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 411-

t	Tube -VW 416 B-

t	Thrust plate -VW 447 H-

t	Hose clip pliers -V.A.G 1275-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Clamp tensioner -V.A.G 1682-

t	Assembly tool -T10065-

t  Multi-purpose tool -VW 771-

t  Removal and assembly tool -T40018- for triple roller joint AAR 3300 i

t  or assembly tool -T40084- for triple roller joint AAR 2600 i t  Brass/copper drift Dismantling triple roller joint AAR 2600 i or 3300 i –  Clamp drive shaft horizontally in vice.   Note t  Use jaw protectors for vice. t  Take care not to damage drive shaft. –  Mark position of joint body relative to drive shaft. 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.

–  Open hose clips -arrows-. –  Push back boot. Distinguishing features of drive shafts AAR 2600 i and AAR 3300 i

–  Measure dimension -A- as shown. t  Dimension -A- 74 mm = drive shaft AAR 2600 i t  Dimension -A- 77 mm = drive shaft AAR 3300 i   Caution It is important to use the correct special tools for the different drive shafts. –  Apply removal and assembly tool -T40018- for triple roller joint AAR 3300 i (or assembly tool -T40084- for triple roller joint AAR 2600 i) behind joint body.

Locating pin -1- must lie against outside of joint body. –  Bring removal and assembly tool into contact with joint body by turning knurled screws -2-.   Note t  Joint body must be fixed in removal and assembly tool -T40018- or -T40084- without play. t  Tighten screws -2- only hand-tight.

–  Screw multi-purpose tool -VW 771- into removal and assembly tool -T40018- or -T40084-. The illustration shows removal and assembly tool -T40018- for drive shaft AAR 3300 i. When working on drive shaft AAR 2600 i use assembly tool -T40084-. –  Remove joint body by knocking horizontally. Leave joint body clamped in removal and assembly tool -T40018- or -T40084-.

–  Mark installation position of components -1- and -2- as shown. 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. 1 -  Drive shaft 2 -  Triple roller spider –  Remove grease with a lint-free cloth.

–  Remove circlip. 1 -  Pliers (commercial type)

–  Press triple roller spider off drive shaft. –  Use the special tools shown in the illustration. 1 -  Assembly tool -T10065/1- 2 -  Assembly tool -T10065/5-, must make contact with base of triple roller spider 3 -  Thrust plate -VW 401- 4 -  Press tool -VW 408 A- 5 -  Thrust plate -VW 402- Assembly tool -T10065/5--2- must not rest on rollers (swivel the rollers aside if necessary). –  Pull off boot. –  Remove grease from shaft splines. –  Check rollers and roller races for wear. –  Clean drive shaft and housing. Assembling triple roller joint AAR 2600 i or 3300 i –  Push on small hose clip with joint boot and bring boot into position on drive shaft (position varies depending on version).

Version with identification groove: –  Position boot in outer groove -arrow B-. The inner groove -arrow A- must remain visible („identification groove“ for correct boot assembly).

Version with drop-centre: –  Position boot between -arrows-.

Pressing triple roller spider onto drive shaft Chamfer on spider faces towards drive shaft and is used as an assembly aid. –  Grease splines -A- on drive shaft lightly with grease used in joint before fitting joint or triple roller spider onto drive shaft. –  Fit triple roller spider onto shaft so that markings are aligned and drive home onto stop.

Use assembly tool -T10065/6--2- and make sure it grips drive shaft at bottom seam -arrow-. –  Use the special tools shown in the illustration. 1 -  Assembly tool -T10065/1- 2 -  Assembly tool -T10065/6- (assembly tool must grip drive shaft at bottom seam -arrow-) 3 -  Thrust plate -VW 401- 4 -  Tube -VW 416 B- 5 -  Thrust plate -VW 447 H- 6 -  Press tool -VW 411- 7 -  Thrust plate -VW 402- Assembly tool -T10065/6--2- must not rest on rollers (swivel the rollers aside if necessary). –  Press triple roller spider onto drive shaft.

–  Fit circlip. –  Circlip must engage audibly. Triple roller spider must lie directly against circlip (zero gap). 1 -  Pliers (commercial type) –  Pack approx. 60 % of drive shaft grease from repair kit into rear of triple roller joint. –  Lightly grease the rollers. Make sure rollers are aligned straight.

–  Use plastic-headed hammer to drive joint body over triple roller spider. The illustration shows removal and assembly tool -T40018- for drive shaft AAR 3300 i. –  Pack remaining quantity of grease into boot. –  Make sure boot is properly positioned on joint body. –  Boot must rest in groove and on contour of joint body

–  Position joint body in central position. See min/max positions in illustration.   Note When setting joint body to centre position, use screwdriver or similar to vent boot -arrow-. –  Install hose clip.   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. –  Tighten hose clips on triple roller joint → Chapter.