Outer CV Joint Service

Fig. 14 Disassembled View Of Outer C/V Joint:

DISASSEMBLY

1. Cut boot clamps from boot and discard boot and clamps.
2. Clean grease from joint.

Fig. 15 Outer C/V Joint Removal From Shaft. Except S.S.G. Units:

3. On A.C.I. and G.K.N. units, support shaft in a soft jawed vise, support outer joint and tap with a mallet to dislodge joint from internal circlip installed in a groove at outer end of shaft. Do not remove slinger from housing.
4. On S.S.G. units, loosen damper weight bolts and slide weight and boot toward inner joint, then expand circlip with suitable pliers, slide joint from shaft and reinstall damper weight.

Fig. 16 Outer C/V Joint Circlip Removal:

5. On all units, remove circlip from shaft groove and discard.
6. On A.C.I. and G.K.N. units, do not remove heavy lock ring from shaft,, unless shaft requires replacement.
7. On all units, if constant velocity joint was operating satisfactorily and grease does not appear contaminated, proceed to "Assembly" procedure, Step 8.
8. If constant velocity joint is noisy or badly worn, replace entire unit. The repair kit will include boot, clamps, circlip and lubricant. Clean and inspect joint as outlined in the following steps.
9. Clean surplus grease and mark relative position of inner cross, cage and housing with a dab of paint.
10. Hold joint vertically in a soft jawed vise.

Fig. 17 Outer C/V Joint Ball Removal:

11. Press downward on one side of inner race to tilt cage and remove ball from opposite side. If joint is tight, use a hammer and a brass drift to tap inner race. Do not strike cage. Repeat this step until all six balls are removed. A screwdriver may be used to pry balls loose.

Fig. 18 Outer C/V Joint Cage & Cross Assembly Removal:

12. Tilt cage assembly vertically and position two opposing, elongated cage windows in area between ball grooves. Remove cage and inner race assembly by pulling upward from housing.

Fig. 19 Cross From Cage Removal. Outer C/V Joints:

13. Rotate inner cross 90 degrees to cage and align one of race spherical lands with an elongated cage window. Raise land into cage window and remove inner race by swinging outward.

INSPECTION

1. Check housing ball races for excessive wear.
2. Check splined shaft and nut threads for damage.
3. Inspect balls for pitting, cracks, scouring and wear. Dulling of the surface is normal.
4. Inspect cage for excessive wear on inner and outer spherical surfaces, heavy brinnelling of cage, window cracks and chipping.
5. Inspect inner race (cross) for excessive wear or scouring of ball races.
6. If any of the defects listed in Steps 1 through 5, are found, replace C/V assembly as a unit.
NOTE: Polished areas in races (cross and housing) and on cage spheres are normal and do not indicate a need for joint replacement unless they are suspected of causing noise and vibration.

ASSEMBLY

CAUTION: Do not use the A.C.I. or G.K.N. boot clamps on the Saginaw hard plastic C/V boots, as these clamps do not have the load capacity to withhold the much greater force needed to clamp plastic boots.
1. If removed, position wear sleeve on joint housing, then tap sleeve onto housing using seal wear sleeve tool No. C-4698 or equivalent.
2. Lightly oil components, then align marks made during disassembly.
3. Align one of the inner race lands with elongated window of cage, then insert race into cage and pivot 90°.
4. Align elongated cage windows with housing land, then pivot cage 90°.
5. Lubricate ball races with one packet of grease from kit.
6. Tilt cage and inner race assembly and insert balls.
7. With shaft supported in a soft jawed vise, install boot.
8. Install snap ring on shaft. Do not overexpand snap ring during installation.
9. Position joint housing on shaft, then engage by tapping sharply with a soft faced mallet.
10. Ensure snap ring is properly seated by attempting to pull joint from shaft.
11. Locate large end of boot over housing and secures boot clamps.