Constant Velocity Joint: Service and Repair

Fig. 6 Halfshaft assemblies. 1982 & 1983 Early Models:

Fig. 7 Separating constant velocity joint from shaft. 1982 & 1983 Early Models:

Fig. 8 Stub shaft stop ring:

1982 & EARLY 1983 MODELS

REMOVAL

Service is the same for both inner and outer constant velocity joints.
1. Place halfshaft in suitable vice. Use caution not to damage boot or clamp.
2. Cut large boot clamp and remove from boot, Fig. 6, then position boot upward on shaft. If boot only is being replaced due to damage, check joint grease for contamination. If joints were operating satisfactorily and grease is not contaminated, add grease and install new boot. If grease is contaminated, joint must be completely disassembled.
3. Separate constant velocity joint from shaft using tool T81P-3514A or equivalent, Fig. 7. If necessary, boot may be removed from shaft by cutting remaining clamp and removing boot.
4. Remove circlip from end of shaft and discard. Inspect stop ring for damage and replace as necessary, Fig. 8.

Fig. 9 Assembling constant velocity joints onto halfshafts:

Fig. 10 Installing constant velocity joint clamp:

Fig. 11 Halfshaft assembled length. 1982 & 1983 Early Models:

INSTALLATION

1. Inspect splines at each end of shaft for damage and wear. Inner constant velocity joint must be installed onto longer splines, Fig. 9.
2. Ensure stop ring is in proper position, then install new circlip into groove nearest end of shaft.
3. Install joint boot until it seats in its groove, then install clamp. Tighten clamp securely but do not damage boot or cut clamp bridge, Fig. 10.
4. Position boot upward towards end of shaft, then position constant velocity joint onto shaft and tap into position using plastic mallet. Joint is fully seated when circlip locks in groove cut into joint bearing inner race. Check for proper seating by trying to pull joint from shaft.
5. Lubricate joints with lubricant packs supplied with service kit. On outer joint, fill boot with 2-3 packet and pack joint with 11-3 packet of lubricant. On inner joint, fill boot with one packet and pack joint with one packet of lubricant. Use lubricant D8RZ-19590A or equivalent only.
6. Position boot over joint, then pry end of boot upward to release any trapped air.
7. Position joint inward or outward as necessary to adjust halfshaft to length shown in Fig. 11.
8. Ensure boot is seated in groove, then refer to step 3 for clamp installation.