Front Drive Axle With 100 mm Dia. Inner Constant Velocity Joint

Inner constant velocity joint, servicing

Removing inner constant velocity joint
- Clamp drive axle in vise.

Use protective jaws.





- Carefully pry off cover using a screwdriver or similar.





- Remove gasket - arrow -.





- Drive off cap from CV boot using a brass or copper drift

Do not open clamp.





- Remove circlip.





- Press inner constant velocity joint off drive axle using special tools shown in illustration.
- Pull inner CV joint boot off drive axle.

Installing inner constant velocity joint





- Apply sealant (hatched area) onto clean inner surface of cap on CV joint boot Sealant bead: continuous, 2 to 3 mm diameter. Route around inside of holes - arrow -.
- Use sealant D 454 300 A2.
- Push joint boot onto drive axle.

Drive axle, boot and contact surface of cap must be free from grease!





- Press on joint up to stop.

Note:
^ Chamfer on inner diameter of ball hub (splines) must face contact collar of drive axle.

Use special tools shown in illustration.

Special tool 40-204 A and the clamping surface on drive axle must be free from grease.





- Install circlip.
- Check that circlip is properly seated.

Always replace circlip.
- Put 50 gram of drive axle grease into boot.

Take care not to damage sealant bead.





- Using bolts - arrows -, align CV joint boot with cap in relation to bolt holes.

The alignment must be very accurate, because no further alignment is possible once the cap has been hammered on.
- Drive on CV joint boot with cap using a plastic hammer.
- Remove surplus sealant immediately as it is pressed out.
- Put 30 grams of drive axle grease through the ball raceways into the constant velocity joint.





- De-grease contact surface for gasket - arrow -.
- Remove adhesive foil from gasket and glue into constant velocity joint.
- Align new cover with bolt holes.

The alignment must be very accurate, because no further alignment is possible once the cover has been pressed on.





- Press on cover using special tools shown in illustration.





- Position CV joint boot between - arrows -.