You will need: flat blade screwdriver, side cutters, punch, hammer, circlip pliers.
1. Remove the front wheel drive assembly (see Removal and installation of front wheel drives).
2. Clean the parts and inspect the drive:
- the outer CV joint must rotate with a slight effort without jerking and jamming, radial and axial play. If present, replace the hinge;
- the inner hinge should move in the angular and axial directions with a slight effort, while jerking, jamming and radial play should not be felt. Otherwise, replace the inner joint;
- the protective covers of the outer and inner hinges must not have cracks or ruptures. Replace damaged cases;
- the wheel drive shaft must not be deformed. Replace warped shaft.
3. For replacement external hinge or its cover disconnect with a screwdriver or bite the clamp with side cutters.
Clamps for fastening the protective covers of the constant-velocity hinges are disposable, replace them with new ones during assembly. As a rule, clamps are included in the kit of a new hinge.
To facilitate removal, the clamp can be sawn with a hacksaw for metal. When sawing the clamp, be careful not to damage the edges of the groove for the cover on the hinge body.
4. Similarly remove the second collar of fastening of a cover.
5. Slide the protective boot off the pivot housing and remove some of the grease from it.
6. Knock off the hinge cage from the shaft with a hammer through the beard, overcoming the force of the retaining ring.
7. Remove the outer joint from the shaft splines.
Attention! Disassembly of the outer hinge is not allowed.
8. Remove the outer hinge cover from the shaft.
Note. When installing the hinge, replace the protective cover with a new one. Usually a boot is included with the new hinge.
9. Unclench the retaining ring with pliers and remove it from the shaft. Replace the circlip regardless of its condition.
10. Before installing a new outer joint, fill its cavity with 100 g of grease (if the hinge has not been lubricated by the manufacturer). Moreover, first fill the hinge body, and then evenly distribute the rest of the amount in the corrugations of the cover.
Note. In the absence of a lubricant recommended by the manufacturer, domestic molybdenum grease SHRUS-4 can be used.
11. Install the outer hinge cover and hinge in the reverse order of removal. When installing the hinge on the shaft, press the hinge with hammer blows on the hinge shank through a soft metal drift until the hinge cage is fixed with the retaining ring.
Attention! Before securing the hinge boot with a large tie, use a screwdriver to pull back on the edge of the boot to equalize the air pressure inside and outside the boot.
12. For replacement Lebro type internal hinge and its cover remove the clamps securing the hinge cover to its body and to the shaft in the same way as was done when removing the outer hinge.
13. Spread the antennae of the retaining ring, at the same time shifting the hinge cage along the splines of the shaft with a beard..
Note. This is how the retaining ring is located in the hinge cage (for clarity shown on the removed hinge).
14.... and remove the inner joint from the shaft.
Attention! Disassembly of the outer hinge is not allowed.
15. Remove the circlip from the groove in the cage.
Note. When assembling, replace the circlip with a new one. As a rule, the ring is included in the kit of the new hinge.
16. Establish a cover of the internal hinge and the hinge in an order, the return to removal. When installing the hinge on the shaft, press the hinge with hammer blows on the hinge shank through a soft metal drift until the hinge cage is fixed with the retaining ring.
17. Before assembly, fill the body cavity and the boot of the inner hinge with approximately 150 g of lubricant: in the hinge - 100 g and in the boot - 50 g.
Note. In the absence of a lubricant recommended by the manufacturer, domestic molybdenum grease SHRUS-4 can be used.
18. Reassemble the inner hinge in the reverse order of disassembly.
19. For replacement internal hinge type Tripod and its cover remove the clamps securing the hinge cover to its body and to the shaft in the same way as was done when removing the outer hinge.
20. If you disassemble the hinge to replace the cover and intend to install the old hinge, mark in any way (e.g. core, needle file or paint) mutual arrangement of the hinge body and the drive shaft.
21. Slide the boot off the hinge housing…
22.... and disconnect the body from the drive.
23. Mark the position of the pivot hub relative to the shaft (see point 20).
24. Prying off the retaining ring of the hinge hub with a screwdriver..
25.... remove the ring from the groove of the shaft.
26. Remove the hub with rollers from the splines of the shaft..
27.... and remove the protective cover from the shaft.
28. Wash all metal parts with kerosene until the old grease is completely removed.
29. Examine rollers, nave and an internal cavity of the case. Seizures, dents and corrosion are not allowed. The rollers should rotate freely on their bearings, without jamming. If malfunctions are found, replace the hinge assembly.
30. Install the hinge cover on the shaft and secure it with a clamp.
31. Install the hinge hub on the splines of the shaft, aligning the marks made during disassembly, and fix it with a retaining ring.
32. Fill the cavity of the inner hinge with grease in an amount of about 100 g. And first fill the hinge body, and then evenly distribute the rest of the amount in the corrugations of the boot.
Note. In the absence of a lubricant recommended by the manufacturer, domestic molybdenum grease SHRUS-4 can be used.
33. Install the hinge housing, aligning the marks made during disassembly.
34. Put a cover on the hinge body and secure it with a collar.
Attention! Before securing the hinge boot with a large tie, use a screwdriver to pull back on the edge of the boot to equalize the air pressure inside and outside the boot.
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