Contents: Assembling the CV joint and…⤓ Installing the outer race (housing)…⤓ Installing the inner CV joint boot ⤓ Installing CV joint boot clamps ⤓
Remove the balls from the separator in the direction shown in Fig. M2 5.013.
Remove the separator from the inner race.
To avoid damaging the boot, cover the splined portion of the shaft with plastic tape before starting work. Then remove the cover from the shaft in the direction shown in Fig. M2 5.015.
Assembling the CV joint and installing the spring retaining ring
Install all CV joint components (balls, separator, inner race) onto the drive shaft and install the retaining spring ring into the groove on the drive shaft.
Installing the outer race (housing) of the CV joint
Apply the required amount of grease to the inside of the outer race and to the housing (see "Lubrication Points").
Install the retaining ring onto the outer race of the hinge, then install the casing onto it and secure it with a small clamp.
Installing the inner CV joint boot
Install the hinge cover so that the distance A is 85±3 mm.
Remove excess air from the housing (if necessary) and install a large compression clamp on the housing. Make sure to install the clamp in the correct direction.
Installing CV joint boot clamps
The small clamp must be installed so that it rests against the protrusion of the boot and provides clearance A (see Fig. M2 5.020).
The clamping clamps are fixed using a special crimping tool (such as shown in Fig. M2 5.021).
When properly secured, the corrugation size B should be between 2.4 mm and 2.8 mm.
The boot should be installed so that the C dimension is between 0.05 mm and 1.55 mm.
The large clamp must be installed so that it rests against the protrusion of the boot and provides clearance D (see Fig. M2 5.024).
When properly fixed, the corrugation size E should be between 2.4 mm and 2.8 mm (see Fig. M2 5.025).
