Note. The internal CV joint cannot be repaired and if it fails, the entire CV joint must be replaced.
Secure the drive shaft in a soft jaw vise.
Using the circlip pliers, remove the circlip from the end of the inner constant velocity joint.
Using a mandrel, knock the protective cover off the hinge.
The mandrel must be installed one by one at different points around the cap perimeter to remove it evenly. Move the protective cover to the middle of the drive shaft.
Secure the inner joint in a vise, then remove the drive shaft from it. If the drive shaft cannot be removed from the hinge, place the hinge under the press and, using the tools, squeeze the drive shaft out of it.
Remove the Belleville spring washer from the drive shaft, after noting its position. The washer is splined and the convex side of the washer is on the hinge side.
Thoroughly clean the drive shaft before installing a new joint.
Install the spring washer onto the shaft so that the convex side of the washer is on the hinge side and the inner splines of the washer are aligned with the splines of the shaft.
Secure the inner CV joint in a soft jaw vise and insert the drive shaft into it. If the shaft does not fit into the joint, press the joint onto the shaft using a press, while the shaft from below must rest on the support.
Install a new circlip into the drive shaft groove.
Fill the inner joint with 120 grams of grease, putting one half of the grease into the joint on one side and the other half on the other side.
Replace the protective cover. Before fastening the protective cover with clamps, use a screwdriver to lift the inner edge of the cover to equalize the air pressure under the cover.
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