Constant Velocity Joint: Service and Repair

Triple-rotor joint, disassembling and assembling

Disassembling





- Open clamp.
- Open clamp on shaft small and push boot back.
- Clamp joint housing in vise (use protective jaw covers).





- Drive screwdriver or similar into cover and pry open.

Note:
^ If the cover will not pry open, insert screwdriver and pry from the opposite side.
^ The cover is destroyed during the removal process. It does not need to be replaced.





- Mark installation position of parts 1, 2 and 3.
1. Triple-rotor joint housing
2. Triple-rotor star
3. Drive axle

Note:
^ Mark parts before disassembly with a waterproof felt-tipped marker.
^ Noises while driving may result if the indicated parts are not reassembled to their prior positrons.

- Remove O-ring (arrow) from groove.
- Hold joint housing and take drive axle out of vise.

CAUTION: Do not let the rollers slide off the triple-rotor star and fall to the floor.

- Hold drive axle and joint in horizontal position and slowly slide joint back.





- Mark installation position of rollers -1- to triple-rotor star -2- using a felt-tinged marker.
- Insert drive axle in vise.
- Remove rollers -1- and place on clean surface.





- Remove circlip.
1. Pliers (commercially available)
- Insert drive axle in press.





- Press triple-rotor star off drive axle.
- Clean shaft and triple-rotor joint housing.

Assembling

- Slide small diameter boot clamp onto shaft.
- Slide triple-rotor joint boot onto shaft.
- Slide triple-rotor joint housing onto shaft.

Assembling triple-rotor star

Note: The chamfer (arrow) on the star goes onto the axle shaft splines first.





- Place triple-rotor star onto shaft according to previous markings and drive onto stop.
- Install circlip and make sure it is correctly seated.
- Install rollers onto triple-rotor star according to previous markings.
- Slide joint housing over rollers and secure (clamp housing in vise).





- Install rectangular sealing ring (arrow) from repair kit into groove.

Note: A seal is formed directly between the triple-rotor joint and the drive flange. The cover is no longer required.

- Press 90 grams of grease from repair kit, into triple-rotor joint.
- Press 90 grams of grease from repair kit behind triple-rotor joint.
- Install joint protective boot.





- Install clamp.





- Tighten small diameter clamp with VAG 1275 pliers or equivalent.





CAUTION:
^ Secure the triple-rotor joint with tape so that the housing is not inadvertently pushed back when installing the drive axle.
^ Remove the tape just prior to bolting the axle to the drive flange.