Front Drive Axle With 108 mm Dia. Inner Constant Velocity Joint

Servicing inner constant velocity joint

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

Use protective jaws.





- Drive cover off with a copper or brass mandrel.





- Remove circlip.
- Remove drive shaft grease and mark installation position of constant velocity joint relative to drive shaft.





- Clamp constant velocity joint with drive shaft in vise, as shown in illustration.
- A second person must hold the drive shaft horizontal to prevent the constant velocity joint from being damaged.
- Open out rim - arrow - of cap slightly using a small chisel.
- Drive cap off with a copper or brass mandrel.





- Press constant velocity joint off drive shaft.
- Take off CV joint boot with cap.

Installing inner constant velocity joint





- Apply sealant D 454 300 A2 on clean inner surface of cover and cap on CV joint boot (hatched area). Route continuous bead of sealant (2..3 mm diameter) around inside of holes - arrow -.

Drive shaft, boot and contact surface of cap must be free from grease!
- Push new boot with cap onto drive shaft.
- Pack 85 g of drive shaft grease into boot.





- Use adhesive tape or similar - arrow - to keep components of constant velocity joint together.
- Press on constant velocity joint.

Note:
^ Chamfer on internal diameter of ball hub (splines) must face drive shaft.

Use the special tools shown in the illustration.

Special tool 40-204 A and the clamping surface on drive shaft must be free from grease.
- Fit circlip.
- Press 35 g of drive shaft grease through the ball raceways into the joint.





- 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.





- Using bolts - arrows -, align new cover in relation to bolt holes.

The alignment must be very accurate, because no further alignment is possible once the part has been hammered on.
- Drive on cover using a plastic hammer.
- Remove surplus sealant immediately as it is pressed out.