Part 1
OVERHAUL FRONT STUB AXLE, CONSTANT VELOCITY JOINT AND SWIVEL ASSEMBLY ON VEHICLES FITTED WITH ABSRemove Stub Axle, Axle Shaft And Constant Velocity Joint
1. Remove the hub complete as described in the operation to overhaul the hub assembly on ABS fitted vehicles.
2. Drain the swivel pin housing and refit plug.
3. Remove the six bolts retaining the stub axle to the swivel housing.
4. Remove the mud shield.
5. Remove the stub axle and joint washer.
6. Pull out the axle shaft and constant velocity joint from the axle casing.
Remove Constant Velocity Joint From Axle Shaft
7. Hold the axle shaft firmly in a soft jawed vice.
8. Using a soft mallet drive the constant velocity joint from the shaft.
9. Remove the circlip and collar from the axle shaft.
Dismantle The Constant Velocity Joint
10. Mark the relative positions of the constant velocity joint inner and outer race and the cage for correct reassembly.
11. Tilt and swivel the cage and inner race to remove the balls.
12. Swivel the cage into line with the axis of the joint and turn it until two opposite windows coincide with two lands of the joint housing.
13. Withdraw the cage.
14. Turn the inner track at right angles to the cage with two of the lands opposite the cage openings and withdraw the inner race.
15. Degrease and examine all components for general wear and condition.
16. Examine the inner and outer track, cage balls and bearing surfaces of the constant velocity joint for damage and excessive wear.
17. To assemble the constant velocity joint, reverse the dismantling instructions and lubricate with a recommended oil.
18. Check that the end-float of the assembled joint does not exceed 0.64 mm (0.025 in).
Fit Constant Velocity Joint To Axle
19. Fit the collar and a new circlip.
20. Engage the constant velocity joint on the axle shaft splines and using a soft mallet, drive the joint home.
Renew Stub Axle, Thrust Ring, Oil Seal And Bearing
21. Drill and chisel off the thrust ring taking care to avoid damaging the stub axle.
22. Remove the bearing and oil seal using special tool 18G 284AAH and slide hammer. Ensure that the fingers of the tool locate behind the bearing to drive it out. Repeat for the oil seal.
REFIT
23. Lubricate the seal and lip with EP90 oil and with the cavity side leading press in a new oil seal using special tool LST 133.
24. Using special tool LST 132, fit bearing with its part number visible when fitted, and flush with the end face of the stub axle.
25. Press fit a new thrust ring onto the stub axle.
Remove Swivel Pin Housing
26. Remove the brake shield secured at the bottom by one nut and bolt, and midway by the lock stop nut.
27. Disconnect the track-rod end ball joint from the housing.
28. Disconnect the drag-link ball joint.
29. Disconnect the jump hoses from the brake jump hose bracket.
30. Remove the ABS brake sensor.
31. Remove the six bolts securing the oil seal and retaining plate to the swivel pin housing. Pry the seal from the swivel pin housing.
NOTE: The oil seal and retaining plate cannot be removed until the swivel pin bearing housing is removed.
32. Remove the two countersunk screws securing the brake damper/shield bracket, and the lower swivel pin to the housing.
33. Withdraw the lower swivel pin and joint washer by tapping the small protruding lug.
34. Remove the top swivel pin retaining bolts complete with the brake jump hose bracket.
35. Withdraw the top swivel pin and shims.
36. Remove the swivel pin housing while retrieving the lower taper bearing.
37. If the swivel pin housing is to be renewed, the drain, level and filler plugs and lock-stop bolt.
Remove And Overhaul Swivel Pin Bearing Housing
38. Remove the seven bolts securing the swivel pin bearing housing to the axle case. Remove the swivel pin bearing housing.
39. Remove and discard the oil seal and joint washer.
40. Drift out the lower swivel pin bearing track.
41. Press out the top swivel pin bush housing assembly. Discard the thrust washer.
42. If worn, pitted or damaged, renew the swivel pin bearing housing.
43. Press in a new lower swivel pin bearing track.
44. Press in a new bush and bush housing. Ensure that the relieved lip of the bush housing faces towards the rear oil seal, as shown.
45. With the seal lips trailing press the axle shaft oil seal flush into the rear of the housing. Grease the lips.
46. Fit a new thrust washer into the top swivel pin bush with the black P.T.F.E. coating uppermost. Check it is in position when fitting the top swivel pin.
47. Hang the swivel pin bearing housing oil seal and retainer plate over the back of the housing. Ensure they are in the correct assembly order.
48. Fit a new joint washer and secure the swivel pin bearing housing to the axle. Starting with the top fixing dowel bolt. Tighten evenly to 65-80 Nm (48-59 ft lb).
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