Constant Velocity Joint Boot: Service and Repair

Boot, driveshaft constant velocity joint, outer

Special tools:
999 5519
951 2619
999 7161

Note: The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Removal

Caution! The constant velocity joint housing must not be disassembled.

Removing drive shafts
Remove the drive shafts.

Removing the boot

Secure the drive shaft in a vise with soft jaws.

Remove:
^ the clamps on the boot
^ the boot.





Wipe off any grease.

Measuring the tripod for the constant velocity joint housing.





Mark up the position of the tripod in relation to the constant velocity joint housing.
Remove by twisting the constant velocity joint housing and tapping the edge by the rollers so that the rollers detach, one at a time.
Use nylon or wooden shims.

Note: Take care when removing the tripod joint (needle bearing rollers).

Removing snap ring

Wipe away any grease from the constant velocity joint housing.
Remove the snap ring for the constant velocity joint housing.





Note: When replacing old components, mark the tripod position in relation to the drive shaft.

Removing the constant velocity joint housing

Remove the constant velocity joint housing. Use 999 7161.
Do not hit the rollers.

Removing vibration damper

Note: Only applies to vehicles equipped with AW55-50/51SN.





Mark up the position of the vibration damper on the drive shaft. Carefully press out the vibration damper from the drive shaft.

Removing the boot on the outer constant velocity joint housing





Remove both the clamps.
Remove the boot.
Wipe off any grease.

Cleaning and checking the outer joint

Note: Do not separate the outer joint.

Clean the assembled constant velocity joint and blow clean.
Check for visible damage.

Lubricate the constant velocity joint thoroughly. See Drive shaft universal joint, gaiter, grease quantity for grease quantity.
Use half the grease packaging. The remainder will be used later in the boot.

Installation

Installing the outer boot





Note: Ensure that there is no grease on the mating surfaces between the boot and the constant velocity joint housing and the drive shaft.

Caution! Ensure that there are no kinks in the boots when the clamps are tightened.

Apply the remaining grease to the inside of the boot.

Remove excess grease. Use isopropanol.

Ensure that the boot is in position on the constant velocity joint housing.
Install a new clamp. Use: 951 2619.





Install the inner and outer clamp. Use 951 2619.

Installing the vibration damper

Note: Only applies to vehicles equipped with AW55-50/51SN.

Clean the drive shaft of grease and dirt.
Install the vibration damper as marked.





Hint: To allow the vibration damper to slide more easily, brush soapy water into the shaft and the hole in the vibration damper.

Installing the boot and tripod





Install:
^ a new boot on the drive shaft with the smaller clamp
^ the tripod according to the marking with the beveled splines on the tripod towards the drive shaft.

Tap in the tripod to its stop. Use: 999 5519.

Install the snap ring, making sure it goes into its groove.

Lubricating with grease

Lubricate the rollers on the tripod with grease.
Apply some grease to the joint housing and the rest in the boot. See Drive shaft universal joint, gaiter, grease quantity for grease quantity.





Installing the constant velocity joint housing





Install the constant velocity joint housing. Use nylon or wooden shims.

Installing and venting the boot

Caution! Ensure that there is no grease on the mating surfaces between the boot and the joint housing. Make sure that no creases form in the boot when the clamps are tightened.

Clean away excess grease with isopropanol. Slide the boot on the constant velocity joint. Ensure that the boot is in position on the constant velocity joint.

Vent the boot.





Install the clamps.





Squeeze together the clamps. Use: 9512619.
Install a new expander ring differential.

Spray wax, part number 30787812, on the outer gaiter.
After installing drive shaft in vehicle, turn the wheel and check, and improve if needed, the wax protection on the gaiter.





Finishing

Installing drive shafts
Install Drive shaft right and Driveshaft left.