Note: Before you start repairing the CV joints, consider simply replacing them with new ones.
1. Remove the drive shaft from the vehicle (see Section 8).
2. Secure the axle in a vice with soft jaws.
Inner CV joint and boot
Ball type
3. Cut off the clamps (see fig. 9.3a). Remove the dust cover (see fig. 9.36).
Fig. 9.3a Cut off the boot clamps
Fig. 9.3b Remove the boot from the hinge housing
Fig. 9.3c Disassembling the inner CV joint: 1 - retaining ring; 2 - separator; 3 - thrust ring; 4 - clamp; 5 - clamp; 6 - case; 7 - ring; 8 - hinge housing; 9 - retaining ring; 10 - clamp; 11 - drive shaft; 12 - case; 13 - clamp.
4. Mark the relative positions of the inner and outer rings, separator and joint shaft to assemble it in the same position.
Fig. 9.4 Applying marks to the hinge parts
5. Remove the wire ring from the outer ring.
Fig. 9.5 Removing the wire ring
6. Remove the outer ring from the joint.
7. Remove the stopper from the axle groove.
Fig. 9.7 Removing the stopper
8. Pull the inner ring off the axle splines. Remove the thrust ring.
9. Use a screwdriver to remove the balls from the separator (see fig. 9.4). Caution: Do not damage the inner ring, balls or cage.
Fig. 9.9 Removing the balls: pry them up with a screwdriver
10. Turn the teeth of the inner ring until they match the holes in the separator and separate them.
Fig. 9.10a Turn the inner ring until the teeth align with the holes in the separator...
Fig. 9.10b... and separate the separator and the inner ring
Inspection
11. Wash all parts. Inspect the separator and rings for pitting, scoring, cracks and other damage. Lightening and polished areas are normal and do not affect the operation of the CV joint.
Assembly
12. Insert the inner ring into the separator so that the chamfer of the ring splines and the small diameter of the separator are on the same side.
Fig. 9.12 Relative position of the inner ring and separator
13. Press the balls into the separator by hand
Fig. 9.13 Installing balls in the separator
14. Wrap the drive shaft splines with electrical tape to prevent damage to the boot. Slide the boot onto the axle. Remove the electrical tape.
15. Install the stop ring into the axle groove. Install the inner ring assembly with the separator. The large diameter of the separator should face outward.
16. Install the retaining ring. Make sure the assembly is tight and secure.
17. Fill the outer ring and boot with the required amount of CV joint grease (usually sold with a new dust cover) Pack the entire joint with grease.
18. Move the outer ring towards the inner ring and install the wire clamp (see fig. 9.5).
19. Wipe off excess grease from the outer ring boot groove. Install the small bore boot into place on the axle. Pull the other end of the boot onto the outer ring and adjust the joint length by rotating the ring.
Fig. 9.19. Before installing the boot mounting clamps, adjust the axle length. The dimensions are given in the specification
20. After adjusting the axle length, equalize the pressure in the boot by inserting a blunt screwdriver between the boot and the outer ring of the joint.
Fig. 9.20 Equalizing pressure inside the hinge
21. Install the boot clamps. Make sure the axle length has not changed.
22. Install a new snap ring onto the axle boss (see 8.10 a, b).
23. Install (see Section 8).
Finger type
Disassembly
24. Cut off the clamps securing the boot and move it towards the center of the axle.
Fig. 9.24 Assembly of a typical pin-type inner CV joint: 1 - spring ring; 2 - stopper; 3 - thrust ring; 4 - clamp; 5 - clamp; 6 - outer CV joint unit; 7 - clamp; 8 - anther; 9 - housing/outer ring of the inner joint; 10 - crosspiece; 11 - anther; 12 - finger; 13 - roller bearing.
25. Mark the relative positions of the outer ring and the crosspiece of the joint so that they can be returned to their place during assembly. Remove the housing.
Fig. 9.25 Applying marks to the hinge parts
26. Remove the retaining ring from the end of the axle and mark the relative positions of the crosspiece and axle (see fig. 9.26), remove the bearings (see fig. 9.27).
Fig. 9.26 Relative position marks (arrows) of the crosspiece and drive shaft
27. Use light hammer blows to remove the crosspiece. Do not lose the bearing rollers or mix them up.
Fig. 9.27 Removing the CV joint crosspiece
28. Remove the thrust ring, pull off the old boot.
Inspection
29. Wash the hinge parts. Mark the roller bearings and their installation locations. Disassemble the bearings one by one and wash them.
30. Inspect the rollers, pins, bearings and outer ring for scoring, pitting and other damage.
Assembly
31. Wrap the axle splines with electrical tape, pull the new boot onto the axle. Install the inner retaining ring.
Fig. 9.31 Install the retaining ring tightly into its groove
32. Orient the crosspiece according to the marks applied and install the crosspiece on the axle using light blows on the bronze drift.
33. Install the outer snap ring.
34. Apply CV joint grease to the inner race of the crosspiece bearings to hold the bearing rollers in place and place the bearings in their places on the crosspiece.
35. Fill half of the total amount of grease into the CV joint halves/rings/housings. Place the housing on the crosspiece, centering it according to the marks made earlier.
36. Install the boot on its mounting places and adjust the axle length (see fig. 9.19).
37. Equalize the pressure in the boot by inserting a screwdriver between the boot and the outer ring (see fig. 9.20).
38. Install new boot clamps and tighten them.
39. Install the drive shaft on the vehicle (see Section 8).
Outer CV joint and boot
Disassembly
40. Following the instructions in steps 3-10 (ball type) or 24-28 (finger type), remove the joint from the axle and disassemble it.
41. If the drive axle is equipped with a dynamic damper, mark the relative position of the axle and damper, cut the clamps and remove the damper.
42. Cut off the CV joint boot clamps and remove it.
Inspection
43. Wash the joint thoroughly. This will be quite difficult since the joint does not disassemble.
44. Bend the joint as much as possible and inspect it for any damage. If damage is found, replace the drive shaft.
Assembly
45. Wrap the splines of the drive shaft with electrical tape and put a new boot on it (Fig. 9.14). Fill the boot with grease from the repair kit that remained after lubricating the joint. Slide the boot onto the joint and tighten the clamps (fig. 9.21a, b).
46. Install the dynamic damper (if used in this design). Make sure the marks you made earlier match up. Install the retaining ring.
47. The process of overhauling the inner hinge, see steps 12-23 (ball type) or 31-38 (cardan type). The installation of the axle shafts is carried out according to the algorithm section 8.