Disassembly and assembly of a hammered tripod joint (Audi Q5-8R)

Table of contents: Disassembly and assembly of the… ↓ Disassembling the tripod joint AAR… ↓ Differences between the drive shafts… ↓ Assembly of the tripod joint AAR… ↓ Press the tripod joint sprocket onto… ↓

Disassembly and assembly of the hammered tripod joint AAR 2600 i or 3300 i

Disassembling the tripod joint AAR 2600 i or 3300 i

Clamp the drive shaft in a vice with protective jaw pads in a horizontal position. Use soft inserts for the vice. Make sure that the drive shaft is not damaged. Mark the position of the hinge part relative to the drive shaft. If they are not marked and installed in the wrong place during assembly, noise may appear later during operation. Mark the position of the boot relative to the hinge. A waterproof felt-tip pen is suitable for applying marks. Open the clamps "arrows". Move the hinge boot back.

Differences between the drive shafts of the AAR 2600 / and AAR 3300 i

Determine the size "A" as shown in Fig.

Dimension "A" 74 mm = drive shaft AAR 2600 i
Dimension "A" 77 mm = drive shaft AAR 3300 i

Caution! Ensure that the correct special tool is used for the specific drive shaft.

Insert the assembly tool "T40018" for the tripod joint AAR 3300 i or the assembly tool "T40084" for the tripod joint AAR 2600 i behind the hinge element. The guide pin "1" must be adjacent to the outer side of the hinge part. Bring the assembly tool to contact the hinge part by turning the knurled screws "2".

The hinge element must be fixed in the assembly tool "T40018" or "T40084" - without any play. Tighten bolts "2" only by hand. Screw the assembly tool "VW 771" into the assembly tool "T40018" or "T40084". The figure shows the assembly tool "T40018" for the drive shaft of the AAR 3300 i.

For the AAR 2600 i drive shaft, use the assembly tool "T40084". Remove the joint by pulling it horizontally with the inertial puller "VW 771". Leave the joint element in the assembly tool "T40018" or "T40084". Mark the installation position of parts "1" and "2" with dashes. If they are not marked and installed in the wrong place during assembly, noise may occur later during operation. A waterproof felt-tip pen is suitable for making marks.

1. Drive shaft
2. Tripod joint sprocket.

Remove grease with a rag that is not frayed. Remove the retaining ring with standard pliers "1".

Press the tripod joint sprocket out of the drive shaft. Use the special tools shown in the picture

1. Mounting device "T10065/1"
2. The mounting device "T10065/5" must fit against the sprocket of the tripod joint
3. Pressure plate "VW 401"
4. Mandrel "VW 408 A"
5. Pressure plate "VW 402"

The mounting device "T10065/5" must not touch the rolling elements of the bearing or move them to the sides. Remove the joint boot. Remove grease from the shaft teeth. Check the wear of the rolling element and guide.

Clean the drive shaft and housing.

Assembly of the tripod joint AAR 2600 / or 3300 i

Slide the small terminal clamp with the hinge cover on and set the hinge cover in the position depending on the design.

Version with marking groove: Position the joint boot in the outer groove "arrow B". The inner groove "arrow A" must not be covered by the "control groove" (to determine the correct installation of the hinge boot).

Version with marking groove: Position the joint boot in the outer groove «arrow B». The inner…

Version with deepened landing groove: Position the joint boot between the "arrows".

Press the tripod joint sprocket onto the drive shaft

The chamfer on the tripod sprocket faces the drive shaft and is designed to facilitate installation. Before installing the hinge or tripod sprocket, the teeth "A" must be coated with a thin layer of grease used for the hinge.

Install the tripod joint sprocket on the shaft in accordance with the marking and push it until it stops. Use the mounting device "T10065/6" and take into account that it engages with the drive shaft at the bottom by the thickening "arrow". Use the special tools shown in the figure.

1. Mounting device "T10065/1"
2. The mounting device "T10065/6" must engage from below with the thickening "arrow" of the drive shaft
3. Pressure plate "VW 401"
4. Tubular insert "VW 416 B"
5. Thrust washer "VW 447 H"
6. Mandrel "VW411"
7. Pressure plate "VW 402"

The mounting device "T10065/6" must not touch the rolling element of the bearing or move it to the sides. Press the tripod joint sprocket onto the drive shaft. Install the retaining ring. The locking ring must lock with an audible click, the sprocket must fit against the locking ring without any play. Inject 70 grams of drive shaft grease from the repair kit into the rear side of the tripod joint. Lightly grease the rolling elements with grease. Make sure that the rolling elements do not warp! Use a plastic hammer to push the joint cage onto the tripod sprocket. The figure shows the assembly tool "T40018" for the AAR 3300 i drive shaft.

Add the remaining grease to the joint boot. Slide the boot onto the joint element. Ensure that the boot is seated correctly on the joint; align the corrugated casing if necessary. The boot should fit in the groove and along the perimeter of the joint housing. When installing the boot on the joint, remove the air from it. This can be done with a screwdriver. Install the clamp. To make it easier to install the cap screws with an internal toothed rim in the head when installing the drive shaft, it is necessary that the eye "2" of the clamp is located between the mounting flanges "1" of the hinge part.