Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling drive shaft with triple roller joint AAR3300i

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 washer -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	Special pliers -V.A.G 1682-

t	Assembly tool -T10065-

t  Multi-purpose tool -VW 771-

t  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

Installation position of dished spring and thrust washer on outer joint 1 -  Dished spring 2 -  Thrust washer –  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. –  Push joint body onto shaft. Fitting triple roller star Drive shaft (tapered version) Chamfer on star faces towards shaft and is used 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 shaft and triple roller star with lubricant paste G 052 142 A2. –  Insert retaining ring, ensuring that it is seated correctly. As of 08.2004, a different grease is used in the triple roller joints. This grease cannot be mixed with the previous one. The triple roller joint must therefore be cleaned before greasing during repair work. –  Press 70 grammes of drive shaft grease from repair set into triple roller joint. –  Slide joint body over rollers and hold. –  Press 60 grammes of drive shaft grease from repair kit into rear of triple roller joint. –  Install joint boot. Fitting triple roller star Drive shaft (cylindrical version)

–  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 70 grammes of drive shaft grease from repair set into triple roller joint. –  Slide joint body over rollers and hold. –  Press 60 grammes of drive shaft grease from repair kit into rear of triple roller joint. –  Install joint boot.

–  Install clamp.   Note To make it easier to insert the multi-point socket-head bolts when installing the drive shaft, position ear -arrow A- of hose clip between mounting flanges -arrows B- of joint body.

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 ears on O-type clip. –  Tighten clamp by turning spindle with a torque wrench (do not cant pliers).   Note t  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-. t  Specified torque: 25 Nm. t  Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g. torque wrench -V.A.G 1331-). t  Make sure thread of spindle -A- on pliers moves freely. Lubricate with MoS2 grease if necessary. t  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 –  Apply special pliers-V.A.G 1682- as shown in diagram. Ensure jaws of tool contact corners -arrows B- of clamp. –  Tighten clamp by turning spindle with a torque wrench (do not cant pliers).

Tightening clamp on small diameter of inner/outer joint Checking outer constant velocity joint → Chapter Checking function of constant velocity joint →