Constant Velocity Joint Boot: Service and Repair

Replacing both gaiters on left and right of output shaft

Remove output shaft, refer to Axle Shaft Assembly, Constant Velocity Type.
Clean output shaft.
Use dust cover repair kit.





Press off sealing cover (1).





Unfasten hose clips (2).
Press cap (3) off together with dust cover.
Remove circlip (4).





Use special tool 26 1 110 corresponding to that diameter on output shaft. Inner bearing race must locate against web of special tool.
Press splined shaft out of constant velocity joint.
In case of hollow shaft, also use special tool 21 2 120.
Do not disassemble the joint.
Check joint for dirt or damage.
Remove gaiter.





Note:
If the joint has to be disassembled (due to dirt), mark position of ball hub, ball cage and joint on the face end with an electric inscriber.
Make sure of absolute cleanliness when assembling.





Unfasten hose clips (5) and (6).
Pull dust cover off over the splined shaft.

Thoroughly clean constant velocity joint while assembled and remove old grease completely.
Insert new grease in joint (supplied with repair kit).
Mount the transmission end dust cover. Remove adhesive tape.
Coat sealing face of cap (3) with sealing gel and press onto constant velocity joint with a pressure ring.
Pull new dust cover on.





Mount special tool 33 2 130.
Press constant velocity joint and cap (3) over inner bearing race on splined shaft.
Install new circlip.





Fill joint with grease.
Pull dust cover onto cap (3).
Fit new hose clips.
The fastener of the large hose clamp must be located between two bores of the constant velocity joint.

Coat sealing faces of cover with sealing gel, and press-fit cover with a pressure ring.