Removing and installing drive shaft, triple roller joint AAR 3700i — VW

Removing and installing drive shaft, triple roller joint AAR 3700i
Special tools and workshop equipment required
Adapter
T10103/1
Bolts
T10103/2
Wedge
T10161
Ball joint puller
T10187
Remover
T10520
Torque wrench
V.A.G 1332
Locking fluid
Electronic Parts Catalogue
Grease
Electronic Parts Catalogue
Procedure for both sides:
Loosen nut for drive shaft
Chapter
.
Caution
Wheel bearings must not be subjected to load after bolt securing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts fitted as this would damage the wheel bearing. If a vehicle nevertheless has to be moved, comply with the following:
Install an outer joint instead of the drive shaft.
Tighten outer joint to 120 Nm.
Loosen wheel bolts.
Raise vehicle
Maintenance
Booklet
20.1
Description of work; Raising vehicle with lifting platform and trolley jack
.
Remove front wheels.
Pull off connectors for brake pad wear indicator and speed sensor.
Unclip both lines from retainer on suspension strut and lay aside.
Vehicles with left/right vehicle level sender
Unscrew nut
1
.
Pull
front left vehicle level sender
G78
/
front right vehicle level sender
G289
2
out of suspension link
3
.
Continuation for all vehicles
Loosen nut
1
on swivel joint but do not remove it completely.
Caution
Leave nut screwed on a few turns to protect thread on pin.
Press suspension link off swivel joint using
ball joint puller
T10187
2
.
Unscrew nut
1
.
Pull suspension link off swivel joint.
Before using
press tool
T10520
ensure that thrust piece
1
is inserted.
Using
press tool
T10520
:
Use
bolts
T10103/2
to secure
adapter
T 10103/1
1
to wheel bearing.
To allow for pressing out drive shaft
3
, secure
press tool
T10520
2
to wheel hub using 3 wheel bolts
3
.
It is essential to follow specified sequence.
I
Tighten knurled nut
1
hand-tight.
II
Turn only bolt
2
using a spanner in order to press out drive shaft with
press tool
T10520
.
Note
At the end of the procedure or for pressing out drive shaft further the spindle must be moved to its original position in order to deploy the hydraulic force!
Note
When pressing out drive shaft, ensure that there is sufficient clearance to all other parts.
Pull wheel bearing housing outwards and place between body and suspension strut using a suitable block of wood.
Push drive shaft in direction of
arrow B
and pull outer joint of drive shaft out of wheel bearing housing.
Removing right drive shaft
»vehicles without four-wheel drive only«
:
Unscrew support bearing
Item
.
Pull out right drive shaft from gearbox splines and remove complete drive shaft.
Continued procedure for left side:
Press off triple roller joint of drive shaft from gearbox housing using
wedge
T10161
.
Remove drive shaft from gearbox splines and pull out complete drive shaft.
Note
When removing the drive shafts, make sure that the triple roller star with rollers is not pulled out of the triple roller joint.
If triple roller star with rollers has slipped out, joint protective boot must be opened and triple roller star with rollers must be re-inserted in triple roller joint.
Installing
Installation is performed in reverse sequence; note the following:
Procedure for both sides:
Note
Before installing the drive shafts, ensure that the O-rings on both sides of the gearbox splines are not damaged. Renew them if necessary.
Installing left drive shaft:
Replace
»old«
circlip of drive shaft with a
»new one«
.
Note
Insert
»new«
circlip directly into groove of drive shaft. It is not permitted for retaining ring to be pushed over splines. This will overstretch retaining ring and render it unusable.
Grease final drive on gearbox
»copiously«
with lubricating grease
Electronic Parts Catalogue
.
Place drive shaft in splines of final drive.
With a hefty
»jolt«
, push drive shaft as far as possible in direction
B
of gearbox.
Note
Make sure that the inner joint is inserted as far as it will go.
The retaining ring must be
»felt«
to engage.
Installing right drive shaft
»vehicles without four-wheel drive only«
:
Grease final drive on gearbox
»copiously«
with lubricating grease
Electronic Parts Catalogue
.
Insert stub shaft on greased splines of final drive.
Tighten support bearing.
Continued procedure for both sides:
Fit drive shaft into wheel bearing.
Remove wooden block between body and suspension strut.
Insert swivel joint in suspension link and tighten suspension link.
Route wiring harness on suspension strut in correct manner and fit electrical connectors.
Tighten 12-point nut
Chapter
.
Install front wheels.
Specified torques
Chapter
“
Assembly overview - drive shafts, triple roller joint AAR 3700i
”
Chapter
“
Assembly overview - subframe
”
Chapter
“
Torque settings for wheel bolts
”