Repair of outer CV joint with diameter 88 mm/100 mm
Remove the outer CV joint. Clamp the drive shaft in a vice with protective jaw pads. Open both clamps and remove the boot from the outer hinge. Using a hammer, use a copper or brass drift -A- to hit the inner ring of the CV joint. Remove the hinge and the hinge boot.
Install the outer CV joint. There should be no grease on the joint boot and drive shaft near the housing seat. Always replace the retaining ring (lock ring) -1- must be replaced. Push on the small terminal clamp with the hinge cover and install the hinge cover in a position depending on the design.
Version with marking groove: Position the joint boot in the outer groove -arrow B-. The inner groove -arrow A- must not close "control groove" (to determine the correct installation of the hinge boot).
Version with deep seat groove: Position the joint boot between -arrows-. Specified amount of lubricant (see table) fill the inside of the hinge.
Before installing the joint, the teeth -A- must be coated with a thin layer of joint lubricant. Insert the retaining ring into the groove of the shaft.
Push the constant velocity joint up to the retaining ring. Align the retaining ring with the hole facing upwards in the center - see. arrows-.
Screw the old axle shaft hinge bolt into the hinge element as shown in the figure.
Press the joint onto the drive shaft with a plastic hammer until the locking ring snaps into place. Specified amount of lubricant (see table) fill the hinge from the cover side. Push the boot onto the hinge element. Release the air from the hinge protective boot. Make sure the boot is in the correct position on the hinge. The boot should fit in the groove and along the perimeter of the hinge body. Tighten the clamps on the outer hinge.
Checking the outer CV joint
The hinge must be disassembled to replace the lubricant if it is heavily soiled, as well as to check the surfaces in contact with the balls for wear and pitting.
Disassembly: Before disassembling, mark the location of the inner race in relation to the separator and body with an engraving machine or a whetstone. Rotate the cage and separator. Remove the balls one by one.
Install the cage with the cage so that the 2 rectangular cutouts of the cage -arrow- align with the protrusions on the outer race of the CV joint (in the hole in the hinge body). Remove the holder and separator.
Turn the side of the hinge cage with the shortened protrusion into the rectangular window of the separator. Remove the cage from the separator.
Check: All 6 balls of each joint have the same nominal size and tolerance. Check splines, cage, race and balls for depressions (pitting) and signs of heavy wear. Too much angular play in the hinge is noticeable when the load changes; in such cases, the hinge must be replaced. Matting of the surface of the balls and the presence of tracks from them are not a reason to replace the hinge.
Assembly
Insert the cage and separator into the hinge body. The separator must be correctly oriented to the sides. Install the balls crosswise. When assembling, install the cage in relation to the separator in accordance with the applied marks. Fill the hinge body with a certain amount of lubricant.
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