Part 1
OVERHAUL STUB AXLE, AXLE SHAFT, CONSTANT VELOCITY JOINT AND SWIVEL PIN ASSEMBLYRemoving Stub Axle, Constant Velocity Joint And Axle Shaft
1. Remove the hub. Wheel Hub
2. Drain the swivel pin housing and refit plug.
3. Remove the six bolts retaining the stub axle to the swivel pin housing.
4. Remove the mud shield, stub axle and joint washer.
5. Remove the brake disc shield secured by one nut and bolt at the bottom front, and one bolt behind the shield, in the swivel pin housing.
6. Disconnect the tie-rod end ball joint from the swivel pin housing.
7. Disconnect the drag-link ball joint.
8. Remove the constant velocity joint from the axle shaft.
9. Remove the spacer from the axle shaft and then the axle shaft from the axle tube.
10. Remove the phosphor bronze bush from the axle shaft.
Dismantling The Constant Velocity Joint
11. Mark the relative positions of the constant velocity joint, inner and outer race and the cage to ensure correct re-assembly.
12. Tilt and swivel the cage and inner race to remove the ball bearings.
13. Swivel the cage into line with the axis of the joint until the two opposite windows coincide with the two lands of the joint housing.
14. Withdraw the cage.
15. Turn the inner track at right angles to the cage with two of the lands opposite the cage openings, and withdraw the inner race.
16. Examine all components for general condition and examine the inner and outer track, cage balls and bearing surfaces of the constant velocity joint for damage and excessive wear. Maximum acceptable end-float on the assembled joint 0.64mm (0.025 in).
17. To assemble the constant velocity joint reverse the dismantling instructions and lubricate with a recommended oil, ensuring that the inner and outer race marks are aligned during assembly.
Overhaul Of Stub Axle
18. Remove the phosphor bronze bush using a suitable hammer and drift.
19. Clean and examine the stub axle. In particular check that the inner seal track diameter is smooth and free from blemishes.
20. Using a suitable block, press or drive-in a new bush up to the shoulder of the stub axle.
Removing The Swivel Pin Housing Assembly
21. Remove the seven bolts securing the swivel pin housing oil seal, retaining plate and joint washer. Release the assembly from the swivel pin housing.
NOTE: While the joint washer can be removed at this stage, the oil seal and retaining plate must remain until the swivel bearing housing is removed.
22. Remove the two bolts, retaining the brake disc shield bracket, and lower swivel pin to the housing.
23. Remove the brake disc shield bracket.
24. Tapping the small protruding lug remove the lower swivel pin and joint washer.
25. Remove the two bolts retaining the brake hose bracket and top swivel pin.
26. Remove the brake hose bracket, top swivel pin and shims.
27. Remove the swivel pin housing while retrieving the lower and upper tapered roller bearings.
28. If the swivel pin housing is to be replaced, remove the drain and level plugs and lock-stop bolt and nut.
Overhaul Of Swivel Bearing Housing
29. Using a suitable drift ease the lower bearing track out of the swivel bearing housing.
NOTE: Use the upper bearing opening for the drift to gain access to the lower bearing track.
30. Remove the seven bolts retaining the swivel bearing housing to the axle case.
31. Pry out the oil seal from the back of the housing also remove the joint washer and discard both.
32. Bolt the swivel bearing housing onto the axle case with the upper bearing track located at the bottom.
33. Drive out the top bearing track from the swivel bearing housing.
NOTE: Use the lower bearing opening for the drift to gain access to the upper bearing track.
34. Remove the bolts from the housing.
35. If worn, pitted or damaged, fit a new housing.
36. Using a suitable tool, seat the upper and lower bearing tracks into the swivel bearing housing.
NOTE: Ensure the bearing tracks are fitted square or damage could occur.
37. With the seal lips trailing press the axle shaft oil seal into the rear of the housing, also grease the lips.
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