31 60 536 Replacing Both Gaiters on Left and Right of Output Shaft

31 60 536 Replacing both gaiters on left and right of output shaft

Special tools required:







Necessary preliminary tasks:
- Remove output shaft.







IMPORTANT:
Repair should 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. 45°.
Remove all traces of old grease from inner joint, wipe out 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 protective jaws when working with a vice.
Used tensioning strap must not be reused.

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







Remove circlip (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 joint on transmission side and carefully clean output shaft.







Press vibration absorber (1), if fitted, off output shaft (2) with press.
Vibration absorber must not be reused.
Replace vibration absorber - Refer to subsequent procedure.







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:
Use only quantity of grease provided.
The joint on the wheel side must not be packed with more than 120 g of grease.
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 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 of grease.

Push packed gaiter together with infinitely variable jubilee clip on to joint on wheel side.
Ensure the gaiter snaps into the groove in the joint and is aligned with the axial marks.
Position a new infinitely variable jubilee clip 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: Gaiters 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) with special tool 32 1 260 .







Pressing on vibration absorber:
Grip output shaft in vice and push vibration absorber (1) by hand onto output shaft.







Ensure the gaiter snaps into the groove in the joint and is aligned with the axial marks.
Adjust vibration absorber (1) so it is positioned a distance (A) = 3 mm from the control groove.

Installation note:
The position of the vibration absorber must be precisely adhered to.
The control groove is still visible after the gaiter is mounted.







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

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







IMPORTANT: Align tripod star such that the bevels face towards the output shaft.

Drive tripod star (1) with a suitable tool (2) onto output shaft until groove for circlip is exposed.







Install circlip (1).







IMPORTANT:
Use only quantity of grease provided.
Packing of grease in the transmission-side joint must not exceed 150 g.

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 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.







IMPORTANT: The circlip must be renewed.







IMPORTANT: In all-wheel drive vehicle, circlip on transfer box must be renewed.