1. Unscrew the two bolts.
2. Remove the brake caliper from the guide
3. Secure the caliper to the chassis with wire. Do not hang the caliper by the hose.
4. Disconnect the steering knuckle from the upper and lower control arms and from the steering rod (see separate description).
5. Use a screwdriver to remove the cover mounting clamp from the hinge housing.
6. Remove the cover by pulling it inward. Pay attention to which direction the end of the clamp points.
7. Use a screwdriver to remove the retaining ring from the groove inside the hinge housing.
8. Remove the shaft from the housing and hub. Be careful not to damage the boot on the end of the shaft hub as it will need to be re-installed.
If necessary, the hinge can be disassembled further. However, this is quite a difficult job. Here is a brief description of it.
1. Thoroughly clean the inside cavity of the joint.
2. Remove the retaining ring from the joint at the end of the shaft.
3. Partially remove the hinge.
4. Use a screwdriver to remove the balls shown in the illustration.
5. Rotate the body half a ball.
6. Slide the separator towards the cover.
7. There is a retaining ring in front of the collar that needs to be removed (using tongs).
8. Remove the collar and housing from the shaft.
9. Remove both covers by unhooking the clamps. Pay attention to how the clamps are installed.
10. Clean all parts thoroughly.
11. Check the hinges for wear. Replace worn parts.
12. Fill the outer joint with special grease. Opel uses grease No. 19 41 52 for this purpose.
13. Fill the cavity of the cover halfway with grease.
14. Secure the cover with a clamp on the outer hinge. Make sure that the cover does not twist and returns to its original place.
15. Attach the inner cover to the drive.
16. Assemble the separator and the clip according to the illustration.
17. Insert the separator so that the smaller diameter points forward.
18. Secure the clip with a retaining ring.
19. The holes for the balls in the separator and the grooves in the cage are aligned by turning the cage by half the diameter of the ball.
20. Press all six balls in order with your hand as shown.
21. Insert the drive shaft into the hub.
22. Secure the inner joint with the retaining ring in the separator.
23. Turn the retaining ring so that its ends are located between the two grooves in the separator.
26. Fill half the volume of the boot with the grease mentioned above.
27. Place the cover on the hinge.
28. Carefully insert a blunt screwdriver under the edge of the case and release the air from the case.
29. Straighten the cover and measure the distance between the ends. It should be 147.5 mm.
30. Secure the cover with clamps. Make sure that the ends of the clamps remain in their original position.
31. Install the caliper, steering knuckle and tie rods as described in the appropriate sections.
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