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:
Special pliers with insert
The special pliers without insert -VAS 1978/1- with insert
for special pliers -VAS 1978/2- is part of the wiring harness
repair set -VAS 1978- and is used to crimp connectors during
wiring harness repairs.
...
Safety precautions during road tests in which test and measuring equipment
is used
Safety precautions during road tests in which test
and measuring equipment is used
Risk of injury due to unsecured test and measuring equipment
If a front passenger airbag is triggered during an accident,
unsecured test and measuring equipment can become dang ...
Recommended all-season tyres
Recommended all-season tyres, worldwide except North America and China
Notes regarding the recommended tyres
→
→ Chapter „Explanations regarding world regions“
Tyre size
Make
Tread pattern
Remarks
195/65&nbs ...
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Dismantling and assembling drive shaft, constant velocity joint VL107
Checking outer constant velocity joint