2. Clean the axle shaft and secure it in a vise.
3. Pry off the sealing cover from the end of the inner CV joint with a lever (see fig. 6.3).
Pic. 6.3. Remove the sealing cap from the end of the inner CV joint
4. Cut/loosen the two collars of the inner CV joint boot and slide the boot along the axle shaft (see fig. 6.4).
Pic. 6.4. Cut the clamps and separate the inner boot from the hinge
5. Wipe off excess grease and remove inner pivot retaining ring from axle shaft (see fig. 6.5).
Pic. 6.5. Remove retaining ring and knock out/pull out inner joint from axle shaft
6. Support the inner member securely and knock out the axle shaft using a hammer and appropriate drift. If the hinge is tight, use a puller to pull the hinge out. Do not disassemble the inner hinge.
7. When the hinge is removed, move the cover from the end of the axle shaft.
8. Loosen the collar of the outer hinge cover, then move the cover along the axle shaft and remove it.
9. Thoroughly clean the CV joints in kerosene or a suitable solvent and dry thoroughly. Inspect the CV joint as follows.
10. Move the inner spline assembly from side to side to inspect each ball in turn at the top of the track. Check balls for cracks, flattening, or pitting.
11. Check the ball tracks on the inner and outer nodes. If the tracks are widened, the balls will not fit tightly. At the same time, check for wear or cracks in the cages. If necessary, the dirt plates can be removed from each pivot assembly and replaced. When installing, make sure that the hinge and cap mating surfaces are clean and dry, then apply a coat of sealant to the cap surface to prevent leaks.
12. If, when checking any of the CV joint parts, it is found to be worn or damaged, the part should be replaced. Inner joints can be purchased separately, but if the outer joint is worn out, the CV joint assembly and axle shaft will have to be replaced. If the joints are in satisfactory condition, purchase a new repair kit, which consists of covers, clamps, a retaining ring of the inner constant velocity joint and special grease.
13. Cover the splined end of the axle shaft with adhesive tape.
14. Put on a new outer cover on the end of the axle shaft.
15. Apply special grease to the outer joint. By turning the hinge, distribute the grease along the bearing tracks and place the rest in a rubber boot (see fig. 6.15).
Pic. 6.15. Put the grease supplied in the repair kit into the outer axle joint
16. Spread the cover over the hinge and check. that the edges of the boot are correctly located on both joints of the axle shaft and the CV joint. Raise the outer edge of the boot to release excess air from the boot (see fig. 6.16, a, b).
Pic. 6.16 a. Slide the new cover into place...
Pic. 6.16b....then lift the outer sealing lip of the boot to release excess air from the boot
17. Install a large metal tie on the case. Tighten the clamp as far as possible and hook the hook into one of the slots. Select the free movement of the clamp by squeezing the raised part of the clamp with special pliers; if special pliers are not available, gently squeeze the clamp using pliers, taking care not to damage the clamp. Fasten the small clamp using the same method (see fig. 6.17, a, b).
Pic. 6.17 a. Tighten the tie-down tie around the cover...
Pic. 6.17b....and take out all the slack by squeezing the raised part of the yoke
18. Put a new cover of the internal hinge on the axle shaft (see fig. 6.18).
Pic. 6.18. Put on a new inner hinge cover, then remove the protective tape (shown by arrow)...
19. Remove the adhesive tape from the axle pins and install the inner CV joint. Press the hinge against the stop on the axle shaft and secure it with a new retaining ring (see fig. 6.19).
Pic. 6.19....and install the inner hinge assembly
20. Put the grease supplied in the repair kit into the inner joint and put the rest in the bag (see fig. 2.20).
Pic. 6.20. Apply special grease to the inner joint
21. Spread the cover over the hinge and check that the edges of the cover are correctly positioned on both connections of the axle shaft and the CV joint. Raise the outer edge of the boot to release excess air from the boot. Fasten the cover with clamps (see point 17).
22. Make sure the mating surfaces of the hinge and cover are clean and dry and apply a coat of sealant to the inner edge of the cover, and press the cover against the inner hinge (see fig. 6.22).
Pic. 6.22. Make sure the sealing mating surface of the cover is clean and dry and apply a coat of sealant before installing it on the inner hinge
23. Check that both CV joints can move freely, then install the axle shafts as described in paragraph 5.