You will need: 15 mm wrenches (two), 32 mm socket head, pliers, wheel nut wrench, mounting blade, hammer, punch.
1. Remove the mudguards and engine crankcase protection (see Removal and installation mudguards and engine crankcase protection).
2. Drain the oil from the gearbox (see Checking the level, topping up and replacing oil in a manual gearbox and working fluid in an automatic gearbox).
3. Remove the wheel (see Wheel replacement).
4. Loosen the front hub nut…
5. …and unscrew the nut.
6. Loosen the nut of the clamp bolt of the front suspension strut ball joint pin to the steering knuckle…
7. …and remove the bolt.
8. Move the shock absorber strut slightly to the side and remove the outer constant velocity joint tailpiece from the hub.
Note: If you cannot remove the joint tailpiece by hand, knock it out of the hub with light blows of a hammer through a punch or a soft metal drift.
Caution: Make sure that the Tripod drive shaft does not come out of the inner joint housing, as this may cause damage to the joint.
9. Using a mounting blade against the gearbox housing, press the inner drive joint out of the axle gear and remove the front wheel drive assembly.
Note. The gap between the inner joint housing and the gearbox housing is very small, it is impossible to insert the end of the mounting blade completely into it at once. After inserting the pointed part of the mounting blade into the gap, carefully hammer the end along the blade to drive it deep into the gap and use it to push the joint housing away from the housing like a wedge until the joint tailstock retaining ring comes out of the axle shaft gear. Then use the blade to finally push the joint tailstock out of the gear.
Caution! When using a tire iron to press out the inner joint from the gearbox axle shaft gear, do not damage the gearbox housing and joint.
Replace the inner joint tailstock snap ring with a new one each time the drive is removed from the vehicle, otherwise the drives may spontaneously detach from the transmission while driving.
10. The second drive is removed in the same way.
11. To install the drive, first insert the splined tail of the outer joint housing into the wheel hub and screw the hub nut until it stops, without tightening it completely.
12. Then insert the splined tailpiece of the inner joint housing into the axle shaft seal and turn the drive shaft slightly so that the splines of the joint tailpiece and the axle shaft gear align.
13. Move the front suspension arm down and, using a sharp movement of the shock absorber strut with the steering knuckle, press the drive into the axle shaft gear until the drive is secured with a retaining ring.
14. Try to pull the inner Lebro-type joint tailpiece out of the axle gear by giving the steering knuckle a sharp tug. If you succeed, repeat the installation of the joint into the gear. If the second attempt does not produce the desired result, replace the inner joint tailpiece retaining ring.
Attention! The described check for the Tripod type joint is carried out almost in the same way, however, you should try to pull the joint tailpiece out of the axle gear by applying force to the joint body, and not to the steering knuckle, otherwise the joint may be damaged.
15. Install the removed parts in the reverse order of removal.
16. Place the vehicle on its wheels, removing it from the supports, and tighten the hub nuts to a torque of 300 Nm.
17. Tighten the wheel nuts (see Wheel replacement).
18. After installing all the parts, fill the gearbox with oil (see Checking the level, topping up and replacing oil in a manual gearbox and working fluid in an automatic gearbox).
19. Install the mudguards and engine crankcase protection (see Removal and installation mudguards and engine crankcase protection).
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