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 joint. Use a hammer through a copper or brass punch "A" to hit the inner CV joint ring. Remove the joint and the joint 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 snap ring (lock ring) "1" must be replaced. Push the small terminal clamp with the hinge cover and set the hinge cover in the position depending on the version.
Version with marking groove: Position the joint boot in the outer groove "arrow B". The inner groove "arrow A" must not be covered by the "control groove" (to determine the correct installation of the hinge boot).
Version with deepened landing groove: Position the joint boot between the "arrows". With the specified amount of grease (see table) fill the inside of the hinge.
Before installing the joint, the teeth "A" must be coated with a thin layer of grease used for the joint. Insert the retaining ring into the groove of the shaft.
Slide the constant velocity joint up to the retaining ring. Align the retaining ring with the hole facing up and in the center "see arrows".
Screw the old axle joint bolt into the joint element as shown in the figure.
Tap the hinge onto the drive shaft with a plastic hammer until the locking ring snaps into place. Apply the specified amount of grease (see table) fill the hinge from the boot side. Slide the boot onto the hinge element. Release air from the hinge protective boot. Ensure that the boot is positioned correctly on the hinge. The boot should fit in the groove and along the perimeter of the hinge housing. Tighten the clamps on the outer hinge.
Checking the outer CV joint
The joint must be disassembled to replace the lubricant if it is heavily contaminated, and to inspect the surfaces that contact the balls for wear and pitting.
Disassembly: Before disassembly, mark the position of the inner race in relation to the separator and body with an engraving machine or a whetstone. Turn the race and separator. Remove the balls one by one.
Install the separator with the cage so that the 2 rectangular cutouts of the separator "arrow" coincide with the protrusions on the outer cage of the CV joint (in the hole of the hinge housing). Remove the clip and separator.
Turn the side of the hinge sleeve with the shortened protrusion into the rectangular window of the separator. Remove the sleeve from the separator.
Check: All 6 balls of each joint have the same nominal size and tolerance. Check the splines, separator, race and balls for pitting and signs of intense wear. Excessive angular clearance in the joint is noticeable when changing the load; in such cases, the joint must be replaced. Matting of the surface of the balls and the presence of tracks from them are not a reason to replace the joint.
Assembly
Insert the cage and separator into the joint housing. The separator must be correctly oriented to the sides. Install the balls crosswise. When assembling, install the cage relative to the separator in accordance with the applied marks. Fill the joint housing with a certain amount of grease.