Protective half shaft covers — replacement (Mercedes-Benz C-Class W201)

1. Remove the axle shafts as described in paragraph 5.

2. Clean the axle shaft and secure it in a vice.

3. Use a lever to pry the sealing cap off the end of the inner CV joint (see fig. 6.3).



4. Cut/loosen the two inner CV joint boot clamps and move the boot along the axle shaft (see fig. 6.4).



5. Wipe off excess grease and remove the inner joint snap ring from the axle shaft (see fig. 6.5).



6. Support the inner member securely and tap out the axle shaft using a hammer and appropriate drift. If the joint is tight, use a puller to pull the joint out. Do not disassemble the inner joint.



7. Once the joint is removed, slide the boot off the end of the axle shaft.

8. Loosen the outer joint boot clamp, then move the boot along the axle shaft and remove it.

9. Clean the CV joints thoroughly in kerosene or a suitable solvent and dry thoroughly. Inspect the CV joint as follows.

10. Move the internal spline assembly from side to side to inspect each ball in turn at the top of the race. Check for cracks, flattening, or pitting on the balls.

11. Check the ball races on the inner and outer joints. If the races are wide, the balls will not fit tightly. At the same time, check for wear or cracks in the separators. If necessary, the mudguards can be removed from each joint and replaced. When installing, make sure the mating surfaces of the joint and cover are clean and dry, then apply a layer of sealant to the surface of the cover to prevent leaks.

12. If any of the CV joint components are found to be worn or damaged during inspection, the component should be replaced. Inner CV joints can be purchased separately, but if the outer CV joint is worn, 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 boots, clamps, an inner CV joint retaining ring, and special grease.

13. Cover the splined end of the axle shaft with tape.

14. Place the new outer boot onto the end of the axle shaft.

15. Put special grease into the outer joint. Turn the joint to distribute the grease along the bearing tracks and put the rest into the rubber boot (see fig. 6.15).





16. Spread the boot over the joint and check that the boot edges are correctly positioned on both axle shaft and CV joint connections. Lift the outer edge of the boot to release excess air from the boot (see Fig. 6.16, a, b).





17. Install a large metal clamp on the cover. Tighten the clamp as much as possible and hook the hook into one of the slots. Select the free play of the clamp by squeezing the raised part of the clamp with special pliers; if you don't have special pliers, carefully squeeze the clamp using pliers, taking precautions not to damage the clamp. Secure the small clamp using a similar method (see Fig. 6.17, a, b).







18. Place the new inner joint boot on the axle shaft (see fig. 6.18).



19. Remove the adhesive tape from the axle shaft splines and install the inner CV joint. Press the joint all the way onto the axle shaft and secure it with a new snap ring (see fig. 6.19).





20. Put the grease supplied in the repair kit into the inner joint and put the rest into the boot (see fig. 2.20).



21. Spread the boot over the joint and check that the boot edges are correctly positioned on both axle shaft and CV joint connections. Lift the outer edge of the boot to release excess air from the boot. Secure the boot with clamps (see item 17).

22. Make sure the mating surfaces of the hinge and cover are clean and dry and apply a layer of sealant to the inner edge of the cover and press the cover until it stops on the inner hinge (see fig. 6.22).



23. Check that both constant velocity joints can move freely, then install the axle shafts as described in paragraph 5.