Constant Velocity Joint Boot: Service and Repair
REPLACEMENT OF RUBBER CUP SEAL ON REAR AXLE SHAFTPreceding work:
Removal and Installation of rear axle shaft (35-620).
Removal, installation
1 Open hose clamps using pincers on the push- out tube and compress. Slide cup seal up to the bead located on the rear axle shaft or cup seal cap and fasten hose clamp. Ensure correct seating at the hose clamp.
2 Remove closing plate and cup seal cap from joint race.
Note: As of 04/91 the rear axle shafts and connection flanges have a centering feature (arrows). Centered connection flanges can be installed with uncentered rear axle shafts (closing plate). However, rear axle shafts with centering feature cannot be combined with connection flanges without centering feature. In such cases a closing plate without centering feature must be installed if required and the grease quantity taken from the installed closing plate.
3 Push back rubber cup seal and cup seal cap on the rear axle shaft. Clean grease off joint.
Installation note: Coat sealing surface of annular joint of closing plate and cup seal cap with sealing compound (e.g. Curil, Loctite 574 or Hylomar) and install. First install the closing plate after packing with grease. Only fill annular joint with the specified lubricant in the quantity specified.
4 Remove circlip. Replace circlip, ensuring correct seating.
5 Press annular joint off rear axle shaft. To do this, use the two shop-made split bearing shells (063a) as well as the pressing on/off tool (063) 116 589 15 15 00.
6 Clean annular joint.
Shop-made Split Bearing Shells:
Installation note: Place clamping jaws on the cup seal collar of the rear axle shaft and using the press-on/press-off tool 116 589 15 15 00 press on up to the contact face of the rear axle shaft (arrow). Clamping jaws for 25 mm dia. rear axle shafts, 116 589 11 31 00 and for 32 mm dia., 116 589 10 31 00.
7 Press annular joint with knurled section (arrow) on circumference of joint race so that knurled section points towards closing plate.
8 Pull cup seal cap and rubber cup seal off of rear axle shaft.
Note: After loosening the hose clamps, the second rubber cup seal can now be withdrawn over the dismantled side of the rear axle shaft, if required. In the process, ensure that none of the grease fill is lost and no dirt can enter the inside of the joint. Wipe off any grease remaining in the inside of the rubber cup seal and pack into the annular joint.
Installation note: If assembly sleeve 115 589 01 63 00 is still present position it on the splined shaft section of the rear axle shaft. Slide rubber cup seal and cup seal cap onto rear axle shaft.
9 Strip down the joint to check the annular joint for wear.
10 Prior to dismantling, mark the position of the joint race, joint hub and ball cage in relation to each other using an electric scriber or whetstone.
11 Swivel joint hub and ball cage and remove balls individually in sequence.
12 Remove joint hub and ball cage from joint race.
13 Swivel joint hub through 90° to the ball cage and remove.
14 Check ball tracks of joint race, joint hub, ball cage and balls for pitting and signs of wear (arrows). If these parts exhibit evidence of wear, the complete annular joint is to be replaced. Smoothed sections and evidence of operation which are caused by the balls do not justify replacement of the annular joint.
Note: A repair kit with all the required parts is available for replacing the cup seal. If a second cup seal is required for the same rear axle shaft, an additional rubber cup seal is to be used for this.
Installation note: Position joint hub at right angles to ball cage and insert. Insert one ball and note marking applied to the joint hub and ball cage.
Install joint hub with ball cage and ball in the joint race and note the marking (arrow).
If the markings have not been applied, install joint race so that the narrow side of the ball track always points to the wide side of the joint hub, or vice versa.
Sixth Ball Installed:
Angle the joint hub and ball cage until one ball can be installed after another.
15 Assemble in reverse sequence.