- special pliers for installing CV joint boot clamps or sliding pliers:
- external snap ring pliers;
- cV joint grease - 40 cm³;
- new hinge cover with new clamps;
- new thrust and retaining rings of the hinge.
Removal
1. Remove the drive assembly ("Front Wheel Drive - Removal and Installation").
2. The ends of all four inner and outer joint clamps on both shafts point in the direction opposite to the drives' forward rotation. To ensure proper assembly, if the clamps are to be reused, use a marker to mark them to indicate the direction of rotation.
3. Using large sliding pliers or special tongs, squeeze the large clamp and use a slotted screwdriver to release the clamp lock.
4. In the same way, remove the small clamp of the outer hinge protective cover.
5. Using a slotted screwdriver, pry up and remove the protective cover from the outer hinge housing.
Tip: A damaged cover can be removed by cutting it with a knife.
Warning: When performing the following operation, if the joint is to be reused, do not strike the separator or the joint housing.
6. Secure the drive shaft in a vice. By striking the inner ring of the joint with a soft metal punch, press the outer joint off the drive shaft.
7. Using a slotted screwdriver, pry up and remove the retaining ring from the drive shaft splines.
Using an external snap ring plier, remove the thrust ring.
9. Remove the protective cover from the drive shaft.
10. Wash the joint in kerosene, wipe with a clean cloth and let dry.
Installation
1. To avoid damaging the new cover during installation, wrap the shaft splines with tape or insulating tape.
2. Put a new protective cover on the shaft, move it to the center of the shaft and remove the tape.
Tip: Do not use a socket head to install the thrust washer. The internal chamfer found on almost all sockets will compress the washer, preventing it from being installed on the shaft.
3. Secure the drive shaft vertically in a vice. Using a 24 mm open-end wrench as a mandrel, install a thrust ring on the splined end of the shaft.
4. Install the retaining ring in the same way.
5. Lubricate the shaft splines with CV joint grease.
6. Install the hinge on the splined end of the shaft. Using a wooden block, press the hinge onto the shaft until it is secured with a locking ring.
Warning! The outer joint requires 40 cm³ of grease.
7. Fill the joint with constant velocity joint grease. Place the remaining grease (40 cm³) into the protective cover.
8. Move the protective cover towards the hinge so that the large sealing belt of the protective cover is completely placed on the hinge housing, and the small sealing belt fits into the groove of the shaft.
9. By lifting the small diameter sealing belt with a slotted screwdriver, we release air from the inner cavity of the cover.
10. Using large sliding pliers or special clamp installation pliers and a slotted screwdriver, install the large and small clamps of the protective cover. Install the clamps taking into account the direction of rotation of the drive. The outer end of the clamps should be directed in the direction opposite to the rotation of the drive when moving forward.
Tip: Before installing the assembled drive on the vehicle, be sure to install a new retaining ring on the splined tailpiece of the inner joint.
11. Install the drive assembly on the vehicle ("Front Wheel Drive - Removal and Installation").