Constant Velocity Joint: Service and Repair

1. Clamp axle shaft in suitable vise.
2. Remove clamp and push dust boot with sealing flange toward inside of axle shaft.
3. Remove circlip.
4. Using suitable tools, press off constant velocity joint.

Fig. 8 Removing hub:

5. Swing out ball hub and ball cage from joint and press out in direction of arrow, Fig. 8. Ball hubs and joints are matched. Do not mix.

Fig. 9 Removing ball cage & hub:

6. Tilt ball hub out of ball cage through ball grove, Fig. 9.
7. Check joint, ball hub, ball cage and balls for pitting. Replace joint if there is excessive radial play in joint.

Fig. 10 Removing ball hub from cage:

8. Place ball hub in ball cage, then press balls into cage, Fig. 10.
9. Install hub with cage and balls pointing up, ensuring after swinging in hub into joint that one wide ball groove on joint is together on one side with a narrow groove of hub. Groove of ball hub and running around periphery of outside diameter on joint must face end of axle shaft.

Fig. 11 Ball bearing installation:

***UPDATED BY TSB-8809 DEC. 1990
10. Swing in ball hub with cage by swinging out hub from cage far enough so that balls are at same distance as grooves, Fig. 11.
11. Push hub with balls into joint.
12. Check operation of joint. CV joint has been properly assembled if ball hub can be pushed back and forth by hand over entire range of travel.
13. Seal large diameter and of new dust boot with suitable adhesive.
14. Using suitable tool, squeeze new clamp between machined shoulders of sealing flange.
15. Replace gasket on flange cover.
16. Push dust boot with sealing flange onto shaft.
17. Pack CV joint from each side with approximately 100 grams of grease, (Optitemp PU 35, part No. 000 043 110 00), supplied in repair kit.
18. Press CV joint onto shaft and install new circlip.
19. Position dust boot correctly, then install clamp.