Disassembly
1. Remove the rear drive shaft, refer to the appropriate section.
2. Loosen the threaded collars, cut the tie-down collars and replace them with threaded ones during installation.
3. Remove the cover of the inner hinge boot from the body and slide towards the drive shaft as follows:
- Clamp the drive shaft in a vise;
- Saw through the cover of the case at an angle of about 45°with a hacksaw so that you get a corner groove.
Attention! In doing so, do not damage the hinge housing;
- Slightly lift the notched top with a screwdriver;
- Take the boot cover with tweezers by the protruding end and screw it on so that the boot cover separates from the hinge body.
Attention! When screwing on, make sure that the drive shaft does not fall out of the swivel ring if the parts are not marked.
4. Wipe off grease from the hinge with a rag.
5. Press the drive shaft out of the inner joint on the press. As a lining, use half rings that rest on the hinge shoulder. Half rings have the following dimensions:
- Outer diameter 50 mm,
- Inner diameter 33 mm,
- Length 50 mm.
6. Remove the inner pivot boot from the drive shaft.
7. If necessary, remove the collars of the outer hinge boot, remove the boot cover and remove the boot through the shaft. When doing this, make sure that dirt does not get into the hinge. Before removing the boot, remove the grease from the inside of the boot and insert it into the hinge.
8. If necessary, wash the joint in gasoline and check the clip tracks for wear and damage. If there is severe wear, the entire joint must be replaced.
9. Clean the rear drive shaft.
Assembly
1. To replace the protective cover, use a repair kit. For extended use, it is also recommended to replace the second cover.
2. Slide the mounting sleeve onto the splines of the drive shaft. If such a sleeve is not available, glue the slots with a protective film so as not to damage the case.
3. Put on a new outer o-ring.
4. Put on the outer cover, as well as the clamps.
5. Put on an internal cover, and also collars on a power shaft.
6. Put on a new inner o-ring.
7. Remove the mounting sleeve and protective film.
8. Slide the inner joint onto the shaft.
9. Clamp the shaft in the area of the shoulder of the cover with a clamping device or in a vise with protective jaws.
10. Press the constant velocity joint with a punch until it stops against the adjacent surface of the rear drive shaft. Then press the joint so that the protrusion of the rear drive shaft is 4.2 mm.
11. Clamp the shaft in a vise so that the hinge hub rests on the half rings. Secure the shaft with a caulk. At the same time, make a new coinage, in the middle between the two already existing ones. For chasing, an appropriate tool with a working part 5–6 mm wide is used.
To avoid damage to the raceways, for example due to tool kickback, embossing should be carried out as close to the splines as possible.
12. Remove the jig.
13. Slide the boot cover onto the appropriate hinge ring as far as it will go.
Attention! When doing this, do not lubricate the sealing ring, otherwise the boot will later rotate on the hinge ring. If necessary, the ring can be put in place with light blows of a plastic hammer.
14. Lock the boot cover with four strokes around the circumference in 90°increments in the groove of the hinge body. Then push the cover with a hammer into the groove of the hinge body. At the same time, make sure that the cover is in the correct position.
15. Fill the cavities and covers of the inner and outer constant velocity joints with 100 g MERСEDES grease. Make sure that dirt does not get into the joints.
16. Put the protective boot on the cover so that the sealing lug of the boot is between the protrusions of the boot cover.
17. Put on covers with a small diameter on the thickening of the power shaft so that after installation the groove of the power shaft is not visible. The thickening of the cover is thus fixed in the first groove of the shaft. Put on the clamps and secure them.
Attention! The clamp screws must face the same direction. On the second boot, install the clamps so that they are offset by 180°with respect to the first boot.
18. Install the drive shaft.