Volkswagen Golf Service & Repair Manual: Dismantling and assembling drive shaft, triple roller joint AAR3300i
| Special tools and workshop equipment required |
| 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- |
| Multi-purpose tool -VW 771- |
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| Removing outer constant velocity
joint |
| – |
Clamp drive shaft in vice using protective jaw covers. |
| – |
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-. |
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| – |
Pull constant velocity joint from drive shaft with puller
-T10382- and multi-purpose tool -VW 771-. |
| 1 - |
Puller plate -T10382/1- |
| 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. |
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| 1 - |
Pliers (commercially available) |
| – |
Set drive shaft into press. |
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| – |
Press triple roller star off drive 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. |
| Chamfer on triple roller star -arrow-
faces towards shaft and serves as an assembly aid. |
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| – |
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. |
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| – |
Slide boot onto boot adapter and ensure that boot engages
correctly in groove -arrow- of
adapter. |
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|
 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. |
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| 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-. |
| 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. |
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| 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).
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| Tightening clamp on small diameter of inner/outer joint |
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Special tools and workshop equipment required
Thrust plate -VW 401-
Thrust plate -VW 402-
Press tool -VW 408 A-
Support ...
The joint is to be dismantled to renew the grease if it is
heavily soiled, or to check the running surfaces of the balls
for wear and damage.
R ...
Other materials:
Removing and installing coolant temperature sender -G62
Removing
Engine cold
–
Briefly open cap of coolant expansion tank
-arrow- in order to release
residual pressure in the cooling system, then tighten the cap
...
Overview of fitting locations – control units, rear
1 -
Remote control receiver for auxiliary coolant heater -R149-
Removing and installing remote control receiver for auxiliary
coolant heater -R149-
→ Heating, Air conditioning; Rep. gr.82
2 -
Two-way signa ...
Assembly overview - D-pillar trim
Note
The illustration shows the D-pillar trim on the left side. The
right-hand side is similar (mirror image of left-hand side).
1 -
D-pillar trim
Removing and installing
→ Chapter
2 -
Retaining cli ...
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Dismantling and assembling drive shaft, constant velocity joint VL107
Checking outer constant velocity joint