D. Repair Procedure 2 - Replacing Circlip

If the gap gauge does not seat fully against the bearing, indicating a gap of less than 9.65 mm, the circlip must be removed, and replaced by a new circlip. The new circlip must be expanded into its recess and checked with the gap gauge.

Note: The following procedure is also applicable should the drive flange have been removed to replace one or more damaged studs.

1. Use suitable circlip pliers to compress and release the circlip from its recess Suitable circlip pliers include Snap-On Blue Point PR-56A.

2. Pull the output flange/drive shaft/bearing assembly, complete with circlip, from the final drive casing. Place a clean cloth in the opening, to prevent possible entry of dust or dirt.





3. Remove and discard the O-ring seal from the drive shaft bearing (Illustration 5.)

4. Hold the drive flange in a vise fitted with soft jaws, as shown in illustration 6. Hold the assembly gently by the drive shaft splines, not by the bearing.














5. Follow the sequence shown in illustrations 6-9 to remove the circlip over the outer end of the drive flange. Do not attempt removal and replacement of the circlip over the bearing end of the drive flange. Damage will occur. Note that the circlip is loose, between the bearing and the drive flange (Illustration 6.) The drive flange has 2 large notches and 2 smaller notches between the set of studs.

6. Raise one end of the circlip through one of the large notches (Illustration 7.)

7. Rotate the circlip counter-clockwise until the opposite end becomes free (Illustration 8.)

8. Remove and discard the circlip (illustration 9.)

9. Install a new circlip over the drive flange. Begin by passing one ear of the circlip over a stud, so that the ear can next pass through and then under one of the large notches in the drive flange (Illustration 9.)








10. Rotate the circlip clockwise (Illustration 10) until the opposite end is pulled down through the notch (Illustration 11.) Use great care to minimize the amount of twisting used during this sequence.

11. Remove the drive flange from the vise and wipe it clean.

12. Lubricate a new O-ring seal with oil and install into the bearing, ensuring that the seal is correctly installed in its groove.

13. Remove the cloth from the aperture and guide the drive shaft into the final drive housing until fully seated.

14. Rotate the flange to provide the most convenient access and use circlip pliers to compress the circlip and allow it to be fully seated in its recess.

15. Tap the circlip towards the center line of the vehicle, expand the circlip in its recess and repeat the measurement process, as previously described in steps 2-4 of Section C. Repair procedure stage 1.

16. If the gap gauge now fits fully between the ears of the circlip, indicating a gap of 9.65 mm or greater, a satisfactory condition has been achieved.

17. Carry out any rectification, as above, required on the opposite side of the vehicle.

18. If the circlips on both sides of the vehicle, following any repairs as detailed above, have been measured with a gap of 9.65 mm or greater, the condition of the vehicle is now satisfactory, and the rear suspension may be reassembled.

19. If a minimum measurement at either circlip of 9.65 mm or greater can not be achieved, following repair action, the vehicle remains in an unsatisfactory condition. The final drive unit must be replaced.

! WARNING: In this situation only, it is permissible to reinstall the original lock nuts to the drive flange studs, as a temporary measure. They must be discarded when the replacement final drive unit is installed.

Revised torque specification:

For nuts & bolts at the drive shaft to pinion flange.

Torque specification: 60 Nm (44 lb ft)