Support - Half Shaft/Short Shaft: Service and Repair

Special Tools
- Standard shaft tool No. 999 1801, or equivalent
- Ring tool No. 999 2853, or equivalent
- Drift tool No. 999 5118, or equivalent
- Press ring tool No. 999 5491, or equivalent
- Drift tool No. 999 5318, or equivalent
- Drift tool No. 999 5519, or equivalent

- Refer to special tool section for additional tool information.

Universal Tool
- Pliers tool No. 981 4215, Or Equivalent

Preparation
- Removing/replacing driveshafts, see:
Axle Shaft Assembly, Constant Velocity Type, Removal steps 1 through 6.
Axle Shaft Assembly, Constant Velocity Type, Installation steps 1 through 4.

NOTE:
- Unless stated otherwise, the Procedure for replacing the support bearing and cleaning the inboard universal joint is the same for both manual and automatic cars.
- The inboard universal joint can only be dismantled in automatic models.

Procedure

Driveshaft, manual models,





1. Exposing inboard universal joint
- Remove clips from inboard boot (gaiter).
- Slide boot (gaiter) off inboard universal joint.





2. Cleaning off grease from universal joint.
Mount driveshaft In vice with gap In circlip pointing upwards.





3. Remove universal joint from driveshaft
- Open circlip to free it from groove and insert a drift between the circlip lugs, refer to Constant Velocity Joint Boot, Replacement. Constant Velocity Joint Boot
- Tap the inner race a few mm along the shaft to hold the circlip open.
- Using a brass drip, tap inboard universal joint off the shaft.

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





4. Clean universal joint thoroughly.
Clean joint in assembled form, as it will not come apart.
To replace support bearing, refer to steps 18 and 19.





5. Install a new circlip on universal joint.
Grease universal joint.
Use grease pack part No. 1161429-4 (120g), or equivalent.
Check that boot (gaiter) is undamaged, or fit new boot onto outboard shaft.





6. Assembling inboard and outboard driveshafts:
Fix outer driveshaft In vice.
- Check that inner race is sitting squarely in universal joint.
Tap shaft into joint.
- Check that circlip is seated in its groove.





7. Pack the remaining grease into joint.

NOTE: Take care not to get any grease on the part of the boot (gaiter) in contact with the joint and shaft.

- Clean off any excess grease using methylated (mineral) spirits.
Slide boot (gaiter) onto the joint and check it is correctly positioned on the driveshaft.
Fit new clips.
- Use pliers tool No. 981 4215, or equivalent.

Driveshaft, automatic transmission AW 50-42





8. Expose inboard universal joint
- Remove clips from inboard boot (gaiter).
- Slide boot (gaiter) off inboard universal joint.

Non-turbo models:





9. Dismantling universal joint
- Mark driveshaft position relative to joint casing.
- Bend casing plate tabs back slightly and remove shaft from joint casing.

Turbo models:





10. Dismantling universal joint
- Mark driveshaft position relative to joint casing.
- Turn back collar of joint casing tab.

NOTE: Turn back properly so spider and needle bearings come well clear of joint casing.

- Remove shaft from joint casing.
- Remove needle bearings from spider.
Mark position relative to spider.





11. Clean joint casing thoroughly
Do not dismantle needle bearings.
Clean off thoroughly with a clean lint-free cloth.
Replacing support bearings, see 018-019.
Replacing boot (gaiter) and outboard driveshaft, see Constant Velocity Joint Boot, Replacement steps 12 through 18. Constant Velocity Joint Boot





12. Only if replacing boot (gaiter):
Remove spider from shaft.
- Mark spider relative to driveshaft markings. Remove circlip.
- Push spider off shaft.
Non-turbo models:
Use drift tool 999 5118 and drift tool 999 5318, or equivalents, as support under spider.
Turbo models:
Use drift tool 999 5118, or equivalent, and put copper or aluminium plates under spider pins to prevent damage to surfaces.
- Remove boot (gaiter) from shaft.





13. Install:
- New boot (gaiter) on driveshaft.
- Spider, lining up as above.

NOTE: Spider's position relative to shaft (non-turbo models only).

Tap spider down until it reaches the stop.
- Use Drift tool No. 999 5519, or equivalent.
Install circlip, making sure it engages in its groove.

Assembling inboard and outboard driveshafts





14. Non-turbo models:
Pack grease into joints.
Use grease pack part No. 1161430-2 (190 g), or equivalent.





15. Turbo models:
Install needle bearings on spider.
- Grease spider pins, use grease pack part No. 1161430-2 (190g), or equivalent.
- Pack grease into joint, use grease pack part No. 1161430-2 (190g), or equivalent.





16. Fit spider onto joint, lining marks up.
Tap plate flaps back properly.
Turbo models:

NOTE: Tap joint tabs back carefully: avoid sharp edges or angles.

Pack remaining grease into joint.

NOTE: Check that no grease gets onto boot (gaiter) where it touches driveshaft or joint.

- Wipe off excess grease with methylated (mineral) spirits.





17. Slide boot (gaiter) over joint.
Check that it is correctly positioned on driveshaft.
Install new cups.
Use pliers tool No. 981 4215, or equivalent.

Replacing support bearing, manual automatic models





18. Remove circlip and support bearing from shaft.
- Use ring tool No. 999 2853, or equivalent.
Support tool and shaft as in picture.





19. Install new bearing and circlip.
Use press ring tool No. 999 5491, or equivalent, as support against circlip.
Put standard shaft tool No. 999 1801, or equivalent, at bottom of joint and push on support bearing and circlip.
Check that support bearing Is resting against its stop.
Now go to:
Manual models: step 6.
Automatic models: step 14.