With Manual Transmission
Drive axle, repairingVehicles with manual transmission
Note: Constant velocity (CV) joints are packed with G6 grease.
Re-grease the joints, if necessary, when replacing the CV joint boots.
1. Circlip
Remove and install with standard circlip pliers
2. Gasket
Always replace, remove protective backing and install on CV joint
3. CV joint, inner
108 mm (4.2 in) outer diameter
Replace only as complete assembly
Removing - Fig. 1
Installing - Fig. 2
4. Boot with cap
With vent hole
Check for cracks and abrasion
Drive off gently with mandrel
Before assembling, seal with D3 on face of CV joint
5. Splined axle shaft
Different lengths for left and right sides
6. Clamp
Always replace
Tightening - Fig. 3
7. CV boot
Check for cracks and abrasion
Before tightening clamp, ventilate CV boot - Fig. 4
8. Clamp
Always replace
Tightening - Fig. 3
9. Dished washer
Installation position Fig. 6
10. Spacer washer
Installation position - Fig. 6
11. Circlip
Always replace
Installation position - Fig. 6
When assembling, install in ring groove on shaft (not visible when CV joint is installed)
12. CV joint, outer
98 mm (3.9 in) outer diameter
Replace only as complete assembly
Removing - Fig. 5
To install, drive CV joint onto shaft with plastic hammer, engage up to circlip
Fig. 1 Pressing off inner CV joint:
Support inner ball hub in this procedure.
Fig. 2 Installing inner CV joint:
Press CV joint on to stop.
Install circlip.
CAUTION: Chamfer on inner diameter of ball hub (splines) must point toward collar on axle shaft.
Fig. 4 Ventilating CV joint boot:
Attaching the CV joint boot onto the outer body of the joint frequently requires compressing or squeezing the boot. This produces a vacuum in the joint boot, which may cause a crease to the inside when driving (arrow).
For this reason, after installing the joint boot, vent it briefly by letting some air in at the small diameter end, thus creating a pressure balance and restoring the correct boot shape.
Clamp drive axle in vice using protective jaws.
Remove boot clamp.
Push back CV joint boot.
Turn in M16 threaded end of special tool 3207 until CV joint is pressed off splined shaft
Fig. 6 Installation position of dished washer, spacer washer and circlip:
1. Circlip
2. Spacer washer
3. Dished washer