VW Golf manuals

Volkswagen Golf Service & Repair Manual: Dismantling and assembling drive shaft, triple roller joint AAR3300i

Volkswagen Golf Service & Repair Manual / Running gear, axles, steering / Front suspension, drive shafts / Drive shaft / Dismantling and assembling drive shaft, triple roller joint AAR3300i

Dismantling and assembling drive shaft, triple roller joint AAR3300i

Special tools and workshop equipment required
Thrust plate -VW 401-
Thrust plate -VW 402-
Press tool -VW 408 A-
Press tool -VW 411-
Tube -VW 416 B-
Thrust washer -VW 447 H-

 
     

Dismantling and assembling drive shaft, triple roller joint AAR3300i

 
Hose clip pliers -V.A.G 1275-
Torque wrench -V.A.G 1331-
Torque wrench -V.A.G 1332-
Special pliers -V.A.G 1682-
Assembly tool -T10065-

 
 
   
Multi-purpose tool -VW 771-
 

Dismantling and assembling drive shaft, triple roller joint AAR3300i

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-.
 

Dismantling and assembling drive shaft, triple roller joint AAR3300i

–  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
–  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.
 

Dismantling and assembling drive shaft, triple roller joint AAR3300i

–  Remove retaining ring.
1 -  Pliers (commercially available)
 -  or -VW 161 A-
–  Set drive shaft into press.
 

Dismantling and assembling drive shaft, triple roller joint AAR3300i

–  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.
Fit triple roller star
Chamfer on triple roller star -arrow- faces towards shaft and serves as an assembly aid.
 

Dismantling and assembling drive shaft, triple roller joint AAR3300i

–  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 half of total amount of grease from repair kit into triple roller joint.
–  Place boot adapter onto joint.
–  Slide joint body over rollers and hold.
–  Press remaining amount of grease from repair kit into rear of triple roller joint.
 

Dismantling and assembling drive shaft, triple roller joint AAR3300i

–  Slide boot onto boot adapter and ensure that boot engages correctly in groove -arrow- of adapter.
 

Dismantling and assembling drive shaft, triple roller joint AAR3300i

–  Install clamp.
  Note
Clamping lug of clamp -arrow A- must be located between securing flanges of joint body -arrows B-. This is the only way of assuring that the multi-point socket head bolts can be guided correctly when installing the drive shaft.
 

Dismantling and assembling drive shaft, triple roller joint AAR3300i

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 ear on O-type clip.
–  Tighten clamp by turning spindle with a torque wrench (do not cant pliers).
  Note
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-.
Specified torque: 25 Nm.
Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g. torque wrench -V.A.G 1331-).
Make sure thread of spindle -A- on pliers moves freely. Lubricate with MoS2 grease if necessary.
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.
 

Dismantling and assembling drive shaft, triple roller joint AAR3300i

Tighten clamp on outer joint
–  Position clamp tensioner -V.A.G 1682- as shown in diagram. Ensure jaws of tensioner lie in corners -arrows B- of ear on O-type clip.
–  Tighten clamp by turning spindle with a torque wrench (do not cant pliers).
 

Dismantling and assembling drive shaft, triple roller joint AAR3300i

Tightening clamp on small diameter of inner/outer joint
 

Dismantling and assembling drive shaft, triple roller joint AAR3300i

Dismantling and assembling drive shaft, constant velocity joint VL107
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