Front Drive Axle with 100 mm dia. Inner Constant Velocity Joint

Inner CV joint, servicing

Inner CV joint, removing

- Drive axle, clamping in vise

Use protective vise covers for this.

- Pry off cap, e.g. with a screwdriver.

- Remove seal - arrow -

- Drive protective joint boot cap under with a brass or copper drift

Clamping sleeves must not be loosened.

- Remove circlip

- Press inner CV joint off of drive axle with special tool shown in illustration.
- Remove inner CV joint protective boot from drive axle.

Inner CV joint, installing

- Apply sealant - hatched surface - to clean surface on inner side of protective joint boot cap. Sealant bead: unbroken, 2 to 3 mm dia. Skirt area around inner holes - arrow -.
- Use sealant D 454 300 A2 for this
- Slide joint protective boot onto drive axle.

- Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.

Protective boot and cap contact surfaces must be free of grease!

- Press on joint until stop.

Chamfer on inner diameter of ball hub (splines) must face contact shoulder of drive axle.

Use special tool shown in illustration.

Press block 40-204 A and clamping surfaces on drive axle must be free of grease.

- Install circlip
- Check circlip for correct seating.

Circlip must be replaced

- Apply 50 g joint grease in boot.

Make sure you do not damage sealant bead.

- Using bolts - arrows -, align protective boot and cap with screw holes.

It must be aligned exactly because it cannot be aligned after driving on.

- Drive off protective boot with cap using plastic hammer.
- Clear away leaking sealing immediately.
- Apply 30 g joint grease in CV joint through ball paths.

- Grease seal contact surface - arrow -.
- Remove adhesive foil from seal and adhere to CV joint.
- Align new cover with screw holes.

It must be aligned exactly because it cannot be aligned after pressing on.

- Press cover on with special tool shown in illustration.

- Position protective joint boot between - arrows -.