31 60 535 Replacing Two Gaiters on Output Shaft(S) (Output Shaft(S) Removed)

31 60 535 - Replacing both gaiters on left or right output shaft (COOPER, COOPER ONE manual transmission)





Special tools required:





Note:
Output shaft removed





Important!
Repair must not be carried out by way of the inner joint! Do not press off or disassemble wheel-side joint.

The transmission-side joint may be bent by max. 18° and the wheel-side joint by max. 45°!

Remove all traces of old grease from inner joint, wipe out old grease in outer joint.

Cleaning may only be carried out with dry, clean and grease- and fluff-free cloths!

Visible fouling on joints (e.g. by water or dirt) will cause premature failure!





Important!
Always use plastic protective jaws when working with a vice.

Old clamping bands must not be reused!

Clean output shaft and grip in vice.

Release clamping bands (1).

Detach housing (2) and clean carefully.





Remove snap ring (1).





Pull tripod star (1) off output shaft with special tool 11 8 310 and clean carefully.





Important!
Remove all traces of old grease. Old gaiter must not be reused!

Detach gaiter (1) of transmission-side joint and clean output shaft carefully.





Removing outer joint gaiter:

Important!
The wheel-side constant-velocity joint is pressed on and secured with a snap ring. Do not press off or disassemble.

Failure to comply with this instruction will result in the constant-velocity joint being damaged.

Mark axial position (1) of gaiter (2) to wheel-side joint (4).

Release clamping bands (3).

Detach gaiter (2) of wheel-side joint.

Wipe accessible areas of hinge (4) with a clean and fluff-free cloth.





Installing outer joint gaiter:

Important!
Packing of grease in the wheel-side joint must not exceed 65 g.

Use only quantity of grease provided.

During assembly, the sealing faces on the gaiter and joint must be clean, dry and free of grease!





Slide new gaiter (1) onto output shaft and fill with lubricating grease from repair kit.

Note:
The sealing surfaces (2) inside the gaiter and the groove on the constant-velocity joint must be dry, clean and free from grease.

Push filled gaiter together with 85.5 mm dia. stepless ear clip onto wheel-side joint.

Make sure that gaiter is engaged in the joint groove and is aligned to the axial markings.

Position new 85.5 mm dia. stepless ear clip in gaiter groove and close with special tool 32 1 260.

Due to the material thickness, an increased closing force is required!

Note:
The diameters of the stepless ear clips are marked on the components!





Important!
Gaiter must be vented after fitting in order to adapt the overpressure generated during fitting to the ambient pressure!

Slide gaiter up to visible groove (1).

Vent gaiter; carefully slide a suitable tool between gaiter and output shaft for this purpose.





Close new 33.5 mm dia. stepless ear clip (1) with special tool 32 1 260.





Installing inner joint gaiter:

Push new gaiter (1) together with 34.6 mm dia. stepless ear clip and 85 mm dia. clamp onto output shaft.

Installation:
Push gaiter of transmission-side joint up to stop of wheel-side gaiter.





Important!
Align tripod star so that chamfer (arrow) points to output shaft.

Drive tripod star with special tool 00 5 500 onto output shaft until groove for snap ring is exposed.





Install new copper-colored snap ring (1).





Important!
Use only quantity of grease provided.

Packing of grease in the transmission-side joint must not exceed 100 g.

Pack lubricating grease provided into housing (1).





Important!
During assembly, the sealing faces on the gaiter and joint must be clean, dry and free of grease!

Attach packed housing (1) to tripod star and into gaiter (2).

Note:
Make sure gaiter is correctly seated in groove of housing.





Important!
Centerpoint of clamping pipe must be situated at height of housing centerline!

Max. deviation (A) ± 10 mm

Close new 85 mm dia. stepless clamp with special tool 31 5 200 31 5 200 Pliers.





Important!
The stepless clamp must snap into place completely with both hooks! Both hooks must no longer be visible after engagement.

Closing travel is 13 mm.

Stepless





Adjust gaiter (1) with housing to 91.5 mm installation length.

Important!
Gaiter must be vented after fitting in order to adapt the overpressure generated during fitting to the ambient pressure!

Vent gaiter (1); carefully slide a suitable tool between gaiter and output shaft for this purpose.

Close new 34.6 mm dia. stepless ear clip (2) with special tool 32 1 260.





Replace transmission snap ring.