Axle Shaft Assembly: Service and Repair

Front Stub Axle, Constant Velocity (CV) Joint and Swivel Pin Housing

Disassmbly

1. Remove front hub assembly.
2. Drain swivel pin housing and install plug.

NOTE: On later vehicles the swivel pin housing is filled with grease for life service. The level and drain plugs have been deleted.





3. Remove 6 bolts retaining stub axle to swivel housing.
4. Remove mud shield.
5. Remove stub axle and joint washer.





6. Pull out axle shaft and constant velocity joint from axle casing.
7. Hold axle shaft firmly in a soft jawed vice.





8. Using a soft mallet drive constant velocity joint from shaft.
9. Remove circlip and collar from axle shaft.






10. Mark positions of constant velocity joint, inner and outer race and cage for reassembly.
11. Swivel cage and inner race to remove balls.
12. Examine all in particular inner and outer track, cage balls and bearing surfaces for damage and excessive wear.
13. Maximum acceptable end-float on assembled joint 0.64 mm (0.025 inch). Renew if worn or damaged. Lubricate with a recommended oil during assembly.

Assembly

1. Install collar and a new circlip.





2. Engage constant velocity joint on axle shaft splines and using a soft mallet, drive joint in fully.
3. Drill and chisel off thrust ring taking care to avoid damaging stub axle.





4. Remove bearing and oil seal using special tool LRT-37-004 and slide hammer LRT-99-004. Ensure lip of tool locates behind bearing to drive it out.
5. Repeat instruction for removal of oil seal.





6. Lubricate seal and lip with EP90 oil and with cavity side leading press in a new oil seal using-special tool LRT-54-004.





7. Using special tool LRT-54-005, install bearing with its part number visible when installed, and flush with end face of stub axle.
8. Press install a new thrust ring onto stub axle.

NOTE: Removal of oil seal and retaining plate is achieved when swivel bearing housing is removed.

9. Remove bolts securing oil seal retaining plate and joint washer. Release assembly from swivel pin housing.
10. Remove 2 bolts, retianing lower swivel pin to housing.
11. Remove brake disc shield bracket.
12. Tap lug to remove lower swivel pin and shims.
13. Remove two bolts retaining brake hose bracket and top swivel pins.
14. Remove bracket, top swivel pin and shims.
15. Remove swivel pin housing while retrieving lower and upper bearings.

NOTE: Use upper bearing opening to gain access to lower bearing track.

16. Remove lower bearing track from swivel bearing housing.
17. Remove 7 bolts securing swivel pin bearing housing to axle case.
18. Remove inner oil seal from back of housing.

NOTE: Use lower bearing opening to gain access to upper bearing track.

19. Remove top bearing track from swivel bearing housing.
20. If worn, pitted or damaged, renew swivel pin bearing housing.

CAUTION: Ensure bearing tracks are fitted square or damage could occur.

21. Install upper and lower bearing tracks to swivel bearing housing.
22. With seal lips trailing press axle shaft oil seal flush into rear of housing. Grease lips.
23. Coat swivel bearing housing to axle casing bolts with sealant, Part No STC 50552.
24. Coat both sides of joint washer with sealing compound. Position swivel bearing housing to axle mating face.
25. Place retaining plate, joint washer and oil seal over flange ready for assembly.
26. Install swivel bearing housing to axle flange with 7 bolts. Tighten to 73 Nm (54 ft. lbs.).
27. Grease and install upper and lower swivel pin taper roller bearings.
28. Position swivel pin housing over swivel bearing housing.
29. Coat joint washer both sides with a sealing compound and position on lower swivel pin.
30. Loosely install brake shield bracket plus lower swivel pin with lug outboard to swivel pin housing.
31. Loosely install top swivel pin plus existing shims and brake hose bracket to swivel pinhousing.
32. Apply sealant, Part No STC 50552, to the threads of lower swivel pin bolts. Tighten to 25 Nm (18 ft. lbs.).
33. Apply sealant, Part No STC 50552, to the threads of lower swivel pin bolts. Install bolts and tighten to 65 Nm (50 ft. lbs.).

NOTE: Swivel housing oil seal and axle should not be fitted.

34. Attach a spring balance to track rod ball joint bore and pull balance to determine effort required to turn swivel pin housing. Resistance, once initial inertia has been overcome, should be 1.16 to 1.46 kg. Adjust be removing or adding shims to top swivel pin.
35. When setting is correct remove top swivel bolts, apply sealant to threads of bolts and tighten to 65 Nm (48 ft. lbs.) and bend over lock tabs.
36. Apply a recommended grease between lips of swivel housing oil seal.
37. Install oil seal, joint washer and retaining plate with 7 bolts and spring washers. Tighten to 11 Nm (96 inch lbs.).
38. Install tie rod and drag link and secure with new cotter pins. Tighten fixings to 40 Nm (30 ft. lbs.)
39. Install brake disc shield.
40. Loosely install lock dtop bolt and nut.
41. Apply a recommended grease between lips of swivel housing oil seal.
42. Secure oil seal with retaining plate and securing bolts. Tighten to 11 Nm (8 ft. lbs.).
43. Install track-rod and drag link and secure with new cotter pins.
44. Loosely install lock stop bolt for later adjustment.
45. Install brake disc shield.

CAUTION: Take care not to damage axle shaft oil seals.

46. Insert axle shaft and when differential splines are engaged, push assembly in fully.
47. Place a new joint washer in position on swivel pin housing to stub axle mating face. Coat threads of stub axle bolts with sealant.
48. Install stub axle with flat at 12 O'clock position.

CAUTION: Ensure that constant velocity joint bearing journal is butted against thrust ring on stub axle before stub axle is secured.

49. Place mud shield in position and secure stub axle to swivel pin housing with six bolts and tighten evenly to 65 Nm (48 ft. lbs.).
50. Install brake jump hoses to brake jump hose bracket.
51. Install front hub complete assembly.
52. Check swivel pin housing oil drain plug is fitted.
53. Remove swivel pin level and filler plugs.

NOTE: Vehicles with a filler plug only must be filled with 0.33 Liters (0.75 pt) of Molytex EP 00 grease

54. Check and top up with new oil until oil runs out from level hole. Allow excess oil to drain and wipe clean.
55. Install swivel pin level and filler plugs.
56. Set steering lock stop bolts.