You will need: flat-blade screwdriver, side cutters, barb, hammer, circlip pliers.
1. Remove the front wheel drive assembly (see «Removal and installation of front wheel drives»).
2. Clean the parts and inspect the drive:
- the outer CV joint must rotate with a slight effort without jerking and jamming, radial and axial play. If present, replace the hinge;
- the inner hinge should move in the angular and axial directions with a slight effort, while jerking, jamming and radial play should not be felt. Otherwise, replace the inner joint;
- the protective covers of the outer and inner hinges must not have cracks or ruptures. Replace damaged cases;
- the wheel drive shaft must not be deformed. Replace warped shaft.
3. To replace the outer hinge or its cover, use a screwdriver to separate...
4.... or have a snack with side cutters...
5....or use pliers to lock the clamp securing the large cover of the outer hinge and remove the clamp.
Note: Clamps for fastening the protective covers of constant velocity joints are disposable, replace them with new ones during assembly. As a rule, clamps are included in the kit of a new hinge.
To facilitate removal, the clamp can be sawn with a hacksaw for metal. When sawing the clamp, be careful not to damage the edges of the groove for the cover on the hinge body.
6. Similarly remove the second collar of fastening of a cover.
7. Slide the protective cover off the hinge housing...
8.... and remove some of the grease from it so that access to the retaining ring opens.
9. Spread the antennae of the retaining ring, while shifting the hinge cage along the splines of the shaft with a beard...
This is how the retaining ring is located in the hinge cage (for clarity shown on the removed hinge).
10.... and remove the outer hinge from the shaft.
Warning: Disassembly of the outer hinge is not permitted.
11. Remove the circlip from the groove in the cage.
When assembling, replace the circlip with a new one. As a rule, the ring is included in the kit of the new hinge.
12. Remove the protective cover from the drive shaft.
Note: When installing the hinge, replace the protective boot with a new one. Usually a boot is included with the new hinge.
Helpful hints: In order not to damage the hinge cover during assembly, wrap the spline of the shaft with insulating tape.
To facilitate installation of the boot on the shaft, lubricate the shaft with a thin layer of lubricant designed to fill the hinge.
13. Before installing a new outer joint, fill its cavity with grease (if the hinge has not been lubricated by the manufacturer) in an amount of about 100 g. And first fill the hinge body, and then evenly distribute the rest of the amount in the corrugations of the cover.
Warning: Do not reduce or increase the recommended amount of grease in the joint.
14. Establish a cover of the external hinge and the hinge in an order, the return to removal. When installing the hinge on the shaft, press the hinge with hammer blows on the hinge shank through a soft metal drift until the hinge cage is fixed with the retaining ring.
Warning: Before securing the hinge boot with a large tie, use a screwdriver to pull back on the edge of the boot to equalize the air pressure inside and outside the boot. If excess air is not removed from under the case, the case may be damaged during operation.
There are some rules for «compression» clamps.
This is what the new one looks like «uncompressed» clamp.
The criterion of correct «compression» clamp is gap A. It should be in the range of 2.4-2.8 mm. If the gap is larger «squeeze» clamp to normal; if less, replace clamp.
15. To disassemble and replace the inner hinge of the Tripod type, remove the clamps that secure the hinge cover to its body...
16.... and to the shaft in the same way as it was done for the outer hinge and the inner hinge of the Lebro type (see above in this subsection).
17. Disconnect the inner pivot housing from the drive.
18. Unclench the retaining ring of the hinge hub with a puller...
19.... and remove the ring by pulling it out of the shaft groove.
Note: Grease has been removed from the hinge for clarity.
When assembling, replace the circlip with a new one. As a rule, the ring is included in the kit of the new hinge. Make sure that the ring is fully inserted into the groove of the shaft.
20. Remove the hub with rollers from the splines of the shaft...
21.... and remove the protective cover from the shaft.
Note: When installing the hinge, replace the protective boot with a new one. Usually a boot is included with the new hinge.
In order not to damage the hinge cover during assembly, wrap the spline of the shaft with insulating tape.
To facilitate installation of the boot on the shaft, lubricate the shaft with a thin layer of lubricant designed to fill the hinge.
22. Wash all metal parts with kerosene until the old grease is completely removed.
23. Before assembly, fill the housing cavity and the boot of the internal hinge with grease in an amount of approximately 150 g: 100 g - in the hinge, 50 g - in the boot.
Warning: Do not reduce or increase the recommended amount of grease in the joint.
24. Assemble the Tripod inner hinge in the reverse order of disassembly.
Warning: Before securing the hinge boot with a large tie, use a screwdriver to pull back on the edge of the boot to equalize the air pressure inside and outside the boot. If excess air is not removed from under the case, the case may be damaged during operation.
There are some rules for «compression» clamps.
The criterion of correct «compression» clamp is gap A. It should be in the range of 2.4-2.8 mm. If the gap is larger «squeeze» clamp to normal; if less, replace clamp.