Constant Velocity Joint Boot: Service and Repair

Special Tools
- Pliers tool no. 981 4215, or equivalent

- Refer to special tool section for additional tool information.

Preparation
- Removing/installing driveshafts, see sections:
Axle Shaft Assembly, Constant Velocity Type, Removal steps 1 through 6.
Axle Shaft Assembly, Constant Velocity Type, Installation steps 1 through 4.
- The Procedure is the same for both LH and RH driveshafts.





NOTE:
- To make removal of driveshaft joints easier, insert a drift as shown.
- The rounding off on the underside (R) prevents the drift from hooking into the driveshaft circlip slot.
- The somewhat acute angle (ca 60°) gives the drift more contact with the inner race.

Procedures





1. Exposing outboard CV joint
- Remove clips from boot (gaiter).
- Remove boot from CV joint.
- Clean CV joint free of grease.
- Put driveshaft in a vice with the gap in the circlip at the top.





2. Remove CV joint from shaft
- Open the circlip to free it from the groove and insert a drift between the circlip lugs as above.
- Tap the inner race a little way along the shaft to hold the circlip open.
- Using a brass drift, tap CV joint off the shaft.

NOTE: Tap inner race only to avoid damaging cage or outer race.

- Remove circlip from CV joint.





3. Remove clips from inboard boot (gaiter) if changing boot.
- Remove boot from driveshaft.
Cleaning and checking outboard CV joints, see steps 4 through 7.

Cleaning inboard CV joints

NOTE: All inboard CV joints (manual and automatic) must be cleaned assembled and blown clean before greasing.

Cleaning/checking outboard CV joints

NOTE: Outboard CV joints can be cleaned in assembled form. For inspection/check Procedures see steps 4 through 8.





4. Mark the relative positions of the outer race, cage and inner race in the CV joint with an electric scriber.





5. Remove balls
- Tilt inner race and cage and remove balls clockwise, one by one.
Use an electric scriber to mark where you started removing the balls.
- Put the balls in order so they can be put back in the same position later.





6. Remove cage and inner ring from shaft.
- Rotate inner race 90° relative to cage.
- Remove inner race.
- Remove circlip from inner race.





7. Clean all CV joint components thoroughly.
If any part shows signs of cracking or scoring, replace entire CV assembly

NOTE: Slight scoring or pitting in races is acceptable.





8. Installing inner race in cage.
- Line up markings and put the first ball in.

NOTE: Carefully note positions of balls.

- Turn inner race and cage.
- Put balls back in their original positions, one by one.





9. Grease CV joint thoroughly.
Insert a new circlip in the joint's inner race.
Grease should also be applied to the back of the joint through the opening for the shaft in the inner race.
Use grease pack:
Part No. 1161428-6 (80g) (non-turbo models), or equivalent
Part No. 1161429-4 (120g) (turbo models), or equivalent





10. Install new boot on driveshaft.
- Fix the driveshaft in a vice.
Install CV Joint on shaft.
- Check that inner race sits square inside the joint.
Tap Joint onto shaft using a plastic mallet.
- Check that circlip is sitting properly in its groove.





11. Apply remaining grease to inner race and cage.

NOTE: Take care not to get any grease on the parts of the boot (gaiter) which come into contact with CV joints or shaft.

Wipe off any excess grease with methylated (mineral) spirits.
Slide boot (gaiter) over CV joint and check that it is correctly positioned on the shaft.
Install new clips.
- Use pliers tool No. 981 4215, or equivalent.