Attention! Do not disassemble the Birfeld CV joint (BJ), except in cases of replacing the protective cover (supplied in the repair kit) of the Birfeld CV joint (BJ).
Caution! Be careful not to damage the rotor mounted on the outer race of the Birfeld CV joint (BJ).
Drive shaft with roller joint
Before replacing the hinge boot, you should measure the distance between the boot clamps, since when installing new boots, it is necessary to maintain this distance to avoid premature wear of the boots.
Disassembly
1. Remove the drive shaft.
2. When replacing a hinge, it is necessary to determine its number, which is located on the cover or on the cover clamp.
Fig. 15.19. Drive shaft: A – left side (cars with 1600 cc and 1900D engines with manual transmission); B – right side (cars with engines of 1600 cm³ and 1900D with manual transmission and 1600 and 1800 cm³ with automatic transmission); 1 – retaining ring; 2 – inner race of the CV joint "Tripod" (TJ) with spherical rollers in assembly; 3 – CV joint cover "Tripod" (TJ); 4 – anther; 5 – CV joint clamp "Tripod" (TJ); 6 – Tripod CV joint housing (TJ); 7 – dynamic damper (for models with petrol engines of 1600 and 1800 cm³); 8 – damper clamp (for models with petrol engines of 1600 and 1800 cm³); 9 – Birfeld CV joint (BJ) assembly
3. Remove housing 6 (Fig. 15.19) of the Tripod CV joint (TJ).
4. Remove the retaining ring 1. Wipe the grease off the CV joint components and use paint or chalk to make alignment marks on the drive shaft and inner race.
5. Secure the CV joint rollers with adhesive tape, then remove the inner race of the Tripod CV joint (TJ) with the spherical rollers assembly.
6. Remove clamp 5 securing the protective cover of the Tripod CV joint drive shaft (TJ).
7. Remove dust cover 4.
8. Remove the protective cover 3 of the Tripod CV joint (TJ).
Attention! 9. Remove clamp 8 of the damper mount (for models with 1600 and 1800 cm³ petrol engines).
Attention! 10. Remove the dynamic damper 7 (for models with petrol engines of 1600 and 1800 cm³).
11. Remove the Birfeld CV joint (BJ) assembly.
Fig. 15.20. Repair kit for the Birfeld constant velocity joint (BJ): 1 – small clamp for fastening the CV joint boot "Birfeld" (BJ); 2 – large clamp for fastening the CV joint boot "Birfeld" (BJ); 3 – cover of the Bierfeld CV joint (BJ)
12. Remove the small clamp 1 (Fig. 15.20) securing the Birfeld (BJ) CV joint boot.
13. Remove the large clamp 2 securing the Birfeld (BJ) CV joint boot.
14. Remove the protective cover 3 of the Birfeld CV joint (BJ). If the cover is to be reinstalled, wrap the shaft splines with adhesive tape before removing the cover.
Examination
1. Thoroughly wash all joint parts with solvent until the old joint grease is completely removed.
2. Check all hinge parts for cracks, nicks, scoring, pitting and uneven wear.
Assembly
1. Wrap the splines of the drive shaft with adhesive tape and slide the new protective boot onto the drive shaft. Remove the adhesive tape.
2. Install the inner race of the Tripod CV joint (TJ) with spherical rollers in assembly, while the previously applied marks on the joint and shaft must be aligned.
3. Install the retaining ring.
4. If the rollers were removed from the inner race, apply a layer of grease to the roller bearings and install the rollers on the inner race axle.
5. Apply half the required amount of grease to the inner joint housing and inner race. When installing the joint housing, check that the alignment marks made when removing the housing match.
6. Install the protective cover and secure it with clamps.
Fig. 15.21. Distance (A) for installing the dynamic damper on the drive shaft: for models with a 1600 cm³ petrol engine (with manual transmission) – left drive shaft A=(264±3) mm, right drive shaft A=(369±3) mm; for models with petrol engines with a capacity of 1600 (automatic transmission) and 1800 cm³ – left drive shaft A=(191±3) mm, right drive shaft A=(371±3) mm
Caution! 7. Install the dynamic damper (for models with 1600 and 1800 cc petrol engines) or the damper clamp (for models with 1600 and 1800 cc petrol engines). Install the dynamic damper as shown in Fig. 15.21.
8. Install the drive shaft.
Drive shaft with ball joint and separator
Attention! On vehicles with F9Q engines and a ball joint and separator, when removing and installing the drive shaft, special care must be taken not to damage the rotors of the wheel speed sensors installed on the outer housings of the Rzeppa CV joints.
On vehicles with F9Q engines and an internal ball joint and separator, the outer constant velocity joint "Rzeppa" (RJ) cannot be disassembled.
On vehicles with F9Q engines, first remove the brake hose retainer, disconnect the speedometer drive cable, disconnect the anti-roll bar and remove the side lower cover.
Disassembly
Fig. 15.22. Drive shaft with ball joint and separator, installed on vehicles with F9Q engines: 1 – Tripod CV joint (TJ) housing of the right wheel drive, assembled; 2 – Tripod CV joint (TJ) housing of the left wheel drive; 3 – retaining ring (left wheel drive shaft); 4 – hinge assembly; 5 – retaining ring; 6 – large clamp of the CV joint boot "Tripod" (TJ); 7 – protective cover for CV joint "Tripod" (TJ); 8 – small clamp of the CV joint boot "Tripod" (TJ); 9 – CV joint "Rzeppa" (RJ) in assembly
1. Remove the clamps securing the protective cover (Fig. 15.22).
2. Remove the protective cover from the inner hinge housing.
3. Remove the inner joint housing from the drive shaft.
4. Clean out old grease from the constant velocity joint.
5. Remove the retaining ring from the end of the drive shaft.
6. Remove the inner ring with balls from the drive shaft.
7. Using paint, mark the relative positions of the inner ring and separator.
8. Using a screwdriver blade, remove the balls from the separator.
9. Rotate the inner ring 90°, aligning the inner ring tabs with the separator windows and remove the inner ring from the separator.
Examination
Using a solvent, clean all the hinge parts. Check the condition of the parts for pitting, scratches, cracks and damage. If there are any defects, replace the hinge assembly.
Assembly
1. Install the inner ring into the separator, aligning the alignment marks.
2. Insert the balls into the separator windows.
3. To avoid damaging the protective cover when installing it on the drive shaft, wrap the splines of the drive shaft with adhesive tape.
4. Slide the small boot retaining clip onto the drive shaft, then the boot and remove the adhesive tape.
5. Install the inner ring and ball assembly onto the drive shaft.
6. Install the retaining ring.
7. Fill the constant velocity joint with fresh grease.
8. Install the inner joint housing onto the drive shaft.
9. Remove excess grease and install the protective boot onto the constant velocity joint housing, then bleed air from under the protective boot.
10. Using a special tool, secure the protective cover with new clamps. Cut off the protruding tail of the clamp.
11. Install the drive shaft.
12. On vehicles with F9Q engines, install the brake hose retainer, disconnect the speedometer drive cable, disconnect the anti-roll bar and remove the side lower cover.