C. Repair Procedure Stage I - Seating Existing Circlip
If the gap gauge does not fit between the ears of the circlip, indicating that the gap is less than the width of the special tool, the following repair is mandatory to attempt to expand the circlip.
1. Use a blunt screwdriver or similar tool, with a small hammer, to gently tap the circlip inwards - towards the center line of the vehicle starting at one ear of the circlip and working around towards the other ear, as shown in illustration 3.
Use care not to damage the circlip or to create burrs on the alloy bearing housing that would prevent expansion of the circlip into its recess.
2. Starting in a position 180° from the gap in the retaining ring, use a blunt screwdriver to attempt to expand the circlip into its recess, pivoting the blade of the screwdriver against the output flange, with its tip prying against the circlip, as shown in illustration 4.
Rotate the output flange to provide access, and repeat the expanding action all around the circlip, prying it at intervals of approximately 300, and working in both directions from the starting point, until the circlip has been expanded further into its recess.
It may be helpful to try to tap the ears of the circlip outwards into the recess, using a hammer with the screwdriver, and with the screwdriver positioned between the output flange and the final drive casing, to achieve the maximum possible expansion of the circlip.
3. Repeat the measurement procedure previously described. If the gap gauge can now be passed between the ears of the circlip, the circlip is adequately seated and no additional action is required.
4. If the gap gauge still does not pass between the ears of the circlip, but the measurement is now greater than the earlier measurement (indicating that the circlip has moved, but by an insufficient amount) repeat steps 1 to 3 above.
5. If a second measurement still not permit the gap gauge to seat fully against the bearing, indicating a gap of less than 9.65 mm, proceed to repair procedure stage 2.