Removal the protective cover from the end of the inner CV joint
Removal the clamps securing the CV joint protective cover
Removal the retaining ring securing the inner CV joint to the drive shaft
Filling the constant velocity joint with grease
Installing a new protective cover on the CV joint
Raising one of the edges of the protective cover to equalize the pressure inside the cover with the atmospheric pressure
Installing the CV joint protective boot mounting clamp
Final tightening of the CV joint protective boot clamp
Installing a new inner CV joint protective boot on the drive shaft
Installing the inner CV joint on the drive shaft
Filling the internal cavities of the CV joint with lubricant
Applying a layer of grease to the inner end of the protective cover
1. Remove the drive shaft.
2. Clean the drive shaft and secure it in a vice with soft jaws.
3. Remove the protective cover from the end of the inner CV joint (see fig. Removing the protective cover from the end of the inner CV joint).
4. Remove the two clamps securing the inner CV joint protective boot and slide the protective boot onto the drive shaft (see fig. Removing the CV joint protective boot fastening clamps).
5. Clean off the grease and remove the inner CV joint retaining ring from the end of the drive shaft (see fig. Removing the retaining ring securing the inner CV joint to the drive shaft).
6. Hold the inner CV joint and use a hammer and drift to tap the drive shaft out of the joint. If the joint is very tight on the shaft, you may need to use a puller. Do not disassemble the inner CV joint.
7. Remove the protective cover by sliding it along the drive shaft.
8. Remove the clamps securing the outer CV joint protective boot and remove it by sliding it along the shaft.
9. Using an appropriate solvent, clean the CV joints and wipe them dry.
10. Rotate the joint hub in sequence so that the balls are in turn at the top point. Check the balls for cracks, deformation or pitting.
11. Check the condition of the ball raceways. If the raceways are broken, the balls will move unevenly along them. Check the holes in the separator for wear and cracks. Replace the protective CV joint covers if necessary. Before installing the covers, clean the mating surfaces of the CV joint and cover and apply a thin layer of grease to the cover.
12. If at least one of the CV joint parts is worn out, the CV joint must be replaced as an assembly. The inner CV joint can be replaced separately, but the outer CV joint is replaced only as an assembly with the drive shaft. When assembling, it is necessary to use new protective covers, new clamps for fastening the protective covers, a new retaining ring for the inner joint of the drive shaft and lubricant.
13. Apply tape to the splines at the end of the drive shaft.
14. Slide the new outer joint boot onto the drive shaft.
15. Fill the outer CV joint cavities with the required amount of lubricant. By moving the joints, distribute the lubricant evenly. Fill the inner cavity of the protective cover with the same lubricant (see fig. Filling the constant velocity joint with grease).
16. Install the protective boot on the CV joint and check that the tabs of the protective boot are correctly positioned on the drive shaft and CV joint housing. Using a screwdriver blade, lift one edge of the protective boot to equalize the pressure inside the protective boot with the atmospheric pressure (see fig. Installing a new protective cover on the CV joint, Raising one of the edges of the protective cover to equalize the pressure inside the cover with the atmospheric pressure).
17. Install the large clamp on the protective cover, tighten it and snap it into place. Using special pliers, finally tighten the clamp securing the drive shaft protective cover. Install the second clamp securing the protective cover in the same way (see fig. Installing the CV joint protective boot clamp, Final tightening of the CV joint protective boot clamp).
18. Slide the new inner CV joint boot onto the drive shaft (see fig. Installing a new inner CV joint protective boot on the drive shaft).
19. Remove the adhesive tape covering the splines of the drive shaft. Install the inner CV joint onto the drive shaft, press it down and secure it with a new retaining ring (see fig. Installing the inner CV joint on the drive shaft).
20. Fill the internal cavities of the CV joint with lubricant, as well as the inside of the protective cover (see fig. Filling the internal cavities of the CV joint with lubricant).
21. Install the protective boot on the CV joint and check that the tabs of the protective boot are correctly installed on the drive shaft and the CV joint housing. Using a screwdriver blade, lift one edge of the protective boot to equalize the pressure inside the boot with the atmospheric pressure.
22. Install the large clamp on the protective cover, tighten it and snap it into place. Using special pliers, finally tighten the clamp securing the protective cover. Install the second clamp securing the protective cover in the same way.
23. Clean the mating surfaces of the CV joint and protective cover and apply a thin layer of grease to the inner end of the protective cover (see Fig. Applying a layer of grease to the inner end of the protective cover).
24. Install the protective cover on the end of the inner joint. Check the smooth movement of the joints, then install the drive shaft.