Rzeppa

Fig. 8 Halfshaft w/Rzeppa Type Constant Velocity Joint:

Models with manual transaxle use a Rzeppa type constant velocity joint at the transaxle end of the halfshaft and a Birfield type constant velocity joint at the hub side of the halfshaft, Fig. 8. The Rzeppa type constant velocity type joint can be disassembled and serviced. The Birfield type constant velocity joint should not be disassembled and is serviced only as an assembly with the halfshaft. To service the Rzeppa type constant velocity joint, proceed as follows:
1. Remove halfshaft as described under ``Halfshaft, Replace.''
2. Position halfshaft in a soft jawed vise.
3. Remove large boot clamp, the roll boot back over shaft, Fig. 8.





4. Check joint grease for contamination, Fig. 9. If grease is not contaminated and joint has been operating satisfactorily, add required amount of lubricant and install a replacement bolt. If grease is contaminated, then constant velocity joint must be disassembled and inspected.

Fig. 10 Bearing Retaining Ring Removal:

5. Place alignment marks on bearing outer race and halfshaft, then remove bearing retaining ring, Fig. 10.
6. Remove outer race.

Fig. 11 Inner Bearing Race Snap Ring Removal:

7. Place alignment marks on bearing inner race and halfshaft, then remove snap ring, Fig. 11.
8. Remove inner race, bearing cage and ball bearing assembly.

Fig. 12 Ball Bearing Removal From Cage:

9. Using a screwdriver with sharp edges filed down, pry ball bearings from cage Fig. 12.
10. Place alignment marks on bearing inner race and bearing cage.
11. Rotate bearing cage inner race to align bearing lands, then remove inner race through large end of cage.
12. If necessary, remove small clamp and boot from halfshaft. If boot is to be reused, wrap halfshaft splines with tape before removing.
13. Check all bearing components for wear and damage. Bearing components are matched during the manufacturing process, therefore components from another constant velocity should not be interchanged. If bearing is found to unsatisfactory, replace the constant velocity joint assembly.
14. Cover halfshaft spline with tape and install boot, if removed.
15. Lubricate inner race, bearing cage and ball bearings with lubricant E43Z-19590-A or equivalent.

Fig. 13 Positioning Inner Bearing Race To Cage:

16. Aligning mark made during disassembly, position inner race into bearing cage. Inner race chamfered splines should face large end of cage, Fig. 13.
17. Using hand pressure, press ball bearings into cage windows.

Fig. 14 Positioning Bearing Cage To Halfshaft:

18. Aligning marks on inner race and halfshaft made during disassembly, position inner race, cage and ball bearing assembly onto halfshaft, then insert snap ring into halfshaft groove. When install bearing assembly on halfshaft, chamfered end of cage should face snap ring, Fig. 14.
19. Apply 1.4 to 2.1 ounces of lubricant E43Z-19590-A or equivalent to outer race, then install outer race over inner race, cage and ball bearing assembly.
20. Add approximately .7 to 1 ounce of lubricant specified in step 19 to outer race, then install outer race bearing retaining ring.

Fig. 15 Position Constant Velocity Joint On Halfshaft:

21. Seat boot in grooves on halfshaft and outer race, then extend constant velocity joint until distance between boot grooves is 3 1/2 inches, Fig. 15. Keep joint at this distance until after boot clamps have been installed.
22. Using a screwdriver with sharp edges filed off, pry up on boot at outer race to allow trapped air to escape.
23. Install and lock boot clamps.
24. Check constant velocity joint for smoothness of operation through its full range of travel.
25. Install halfshaft on vehicle as described under ``Halfshaft, Replace.''