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Hold triple-rotor joint and remove axle shaft from vise. Hold axle shaft and triple-rotor joint housing 5. Using felt tipped pen, mark relative positions of rollers (1) and triple-rotor star (2). See Fig. 35 . 6. Remove rollers (1) and place on clean surface. Install axle shaft in press. Using pliers, remove circlip. See Fig. 36 . 7. Install axle shaft in press. See Fig. 33 . Hold axle shaft, and press triple-rotor star off axle shaft. Pull joint together with triple-rotor joint boot off shaft. Clean shaft and housing. 8. Slide triple-rotor joint boot clamp onto shaft. Slide triple-rotor joint boot onto shaft. Slide triple-rotor housing joint onto shaft. 9. Using a press, install triple-rotor star onto shaft stop. Install NEW circlip, ensuring it is seated correctly. 10. Press specified amount of grease from repair kit, into triple roller joint and reverse side of triple-roller joint. See TRIPLE ROLLER JOINT (AAR 2900) table under LUBRICATION. Place seal from repair 11. Install axle shaft in press. Press cover into triple roller joint until circlip can be installed. Insert circlip, 12. Install joint protective cover. Position triple roller joint approximately in middle of sliding part, between "min" and "max". Hold triple roller joint in this position and lift boot slightly (arrow) to vent boot. See 13. Install NEW cover, positioning tabs on straight surfaces of joint housing. See Fig. 31 . Holes of cover and 14. Install axle shaft. See FRONT AXLE SHAFT under REMOVAL & INSTALLATION. CAUTION: Ensure rollers DO NOT slide off triple-rotor star and fall off. CAUTION: Ensure pressure does not exceed 6000 psi when pressing axle onto stop. NOTE: Bevel on star faces toward shaft. This is used as an assembly aid.If NOTE: Circlip must be heard when it seats. NOTE: Holes of cover and joint housing must align.
2003 Volkswagen New Beetle GLS 1998-04 DRIVE AXLES Axle Shafts - New Beetle
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