31 60 535 Replacing Both Gaiters on Left or Right Output Shaft

31 60 535 Replacing Both Gaiters On Left Or Right Output Shaft (Cooper, Cooper One MT)

Special tools required:







NOTE: Output shaft removed.







IMPORTANT:
Repair may only be carried out via 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. 451
Remove all traces of old grease from inner joint, wipe off old grease from outer joint.
Only use dry, clean cloth free of grease and lint for cleaning.
Visible soiling of joints (e.g. by water or dirt) will cause premature failure.







IMPORTANT:
Always use plastic vice jaw protectors when working with a vice.
Tensioning straps are not to be reused.

Clean output shaft and grip in vice.
Release clamping bands (1).
Detach housing (2) and clean carefully.







Remove circlip (1).







Pull off tripod star (1) from 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 joint on transmission side and carefully clean output shaft.







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 damage to the constant velocity joint.

Mark axial position (1) of gaiter (2) to wheel-side joint (4).
Release clamping bands (3).
Detach gaiter (2) of joint on wheel side.
Wipe accessible areas of joint (4) with a clean and lint-free cloth.







Installing outer joint gaiter:

IMPORTANT:
The wheel-side joint must not be repacked with more than 65 g of grease.
Only use grease from the repair kit or as specified in the Electronic Parts Catalogue.
During assembly, the sealing surfaces on the gaiter and joint must be clean, dry and free of grease.







Slide new gaiter (1) onto output shaft and pack with lubricating grease.

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

Push filled gaiter together with infinitely variable jubilee clip dia. 85.5 mm on to wheel-side joint.
Ensure the gaiter snaps into the groove in the joint and is aligned with the axial marks.

Position a new infinitely variable jubilee clip dia.85.5 mm in the groove for the gaiter 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 bled after fitting in order to adapt the excess pressure generated during fitting to the ambient pressure.

Slide gaiter up to visible groove (1).
Bleed gaiter; carefully slide a suitable tool between gaiter and output shaft for this purpose.







Close new infinitely variable jubilee clip (1) dia.33.5 mm with special tool 32 1 260.







Installing inner joint gaiter:
Slide new gaiter (1) together with infinitely variable jubilee clip dia. 34.6 mm and retaining clip dia. 85 mm on to output shaft.

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







IMPORTANT: Align tripod star so that phase (arrow) points towards output shaft.

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







Install new copper coloured circlip (1).







IMPORTANT:
Packing of grease in the transmission-side joint must not exceed 100 g.
Only use grease from the repair kit or as specified in the Electronic Parts Catalogue.

Pack lubricating grease into housing (1).







IMPORTANT: During assembly, the sealing surfaces 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 in housing.







IMPORTANT:
The centre point of clip must be level with the centre line of the housing.
Max. deviation (A) ± 10 mm

Close new infinitely variable retaining clip dia.85 mm with special tool 31 5 200.







IMPORTANT:
The stepless clamp must snap into place completely with both hooks. Both hooks must no longer be visible after engagement.
The closing travel is 13 mm
STEPless







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

IMPORTANT: Gaiter must be bled after fitting in order to adapt the excess pressure 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 infinitely variable jubilee clip (2) dia.34.6 mm with special tool 32 1 260.







Renew transmission circlip.