Front Drive Axle with 108 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.





- Drive cover down with copper or brass drift





- Remove circlip
- Remove joint grease and mark location of CV joint to drive axle.





- Clamp drive axle in vise at CV joint, as shown in illustration.
- A 2nd technician must hold drive axle horizontally so that CV joint is not damaged.
- Bend edge - arrow - of cap up slightly with small flat chisel.
- Drive cap down with copper or brass drift





- Press CV joint off of drive axle.
- Remove protective boot with cap.

Inner CV joint, installing





- Apply sealant D 454 300 A2 - hatched surface - to clean surface on inner side of protective boot cover or cap, and. Sealant bead: unbroken, 2 to 3 mm dia., skirt area around inner holes - arrow -.

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

- Slide new protective boot with cap onto drive axle.

- Pack 85 g joint grease into boot.





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





- Secure CV joint from coming apart, e.g. with adhesive tape - arrow -.
- Press off CV joint.

Note:
^ Position ball hub with chamfer on inner diameter (splines) on 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
- Press 35 g joint grease into joint through ball races.





- 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 sealant immediately.





- Align new cover with bolts - arrows - to screw holes.

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

- Drive cover on with a plastic hammer.
- Clear away leaking sealing immediately.