Axle Shaft Assembly

AR35.30-P-0661-01P Boot cap on joint ring removal and installation
- with rear axle set

Modification Notes:

Rear Axle Shaft, Plugged In Shafts:

Remove boot cap

Component Identification:

1 Using protective jaw pads, clamp rear halfshaft into vice.
2 Using a hand coping saw, saw cup seal (37i) radially in the groove on the press-in edge so that a notch arises.

Avoid damaging the joint ring (37c).

Component Identification:

3 Use a screwdriver to lift the notched area.

Component Identification:

4 Starting at the standing away end, unscrew cup seal (37i) using suitable pliers until it is possible to lift the cup seal (37i) off the joint ring (37c).

When unscrewing the cup seal (37i) ensure that the rear axle shaft does not fall out of the joint ring (37c) before the parts have match marks placed.

5 Remove hose clamps (37k).
6 Pull boot (37l) with cup seal (37i) off joint ring (37c) and slide away on the rear axle shaft.

When replacing both boots (37l) the opposite boot (37l) can be slid over the rear axle shaft

Install boot cap.

Component Identification:

7 Replace O-ring on joint ring (37c).

To facilitate assembly of the cup seal (37i), rub O-ring with spirit.

Do not grease or oil the O-ring, as this might cause the cap seal (37i) to turn on the joint ring (37c).

8 Mount cup seal (37i) with hose clamp (37k) and slide on as far as the end stop on the joint ring (37c). If necessary, drive fully home by tapping gently with a plastic mallet.

Slide on cup seal (37i) carefully otherwise the O-ring will be damaged.

9 By four blows on the circumference, offset by 90 degrees respectively, fix cup seal (37i) in place in the circumferential groove of the joint ring (37c).

Component Identification:

10 By means of even blows with a suitable hammer drive cup seal (37i) into the circumferential groove of the joint ring (37c).

Ensure that the boot cap (37i) seats properly.

Component Identification:

11 By positioning a drift ([diameter]4 mm) and applying even blows with the hammer, reposition the cup seal (37i) in the groove.

Component Identification:

12 Measure size of joint housing.

The quantity of grease required depends on the size of the joint housing. Using a vernier caliper determine diameter "A" on the outside of ball joint and diameter "B" on the inside of the ball joint.

For measuring points, see arrows. For quantity of grease, see Table.

Component Identification:

13 Fill joint with new grease
14 Slide boot (37l) onto cup seal (37i).

Ensure that the ridge (arrow) on the boot (37l) is resting between the ridges on the boot cap (37i).

After the boot (37l) is slid on, no grooves on the rear halfshaft should be visible at the end with the smaller diameter, this indicates that the ridge (37l) on the boot is in the first groove.

Component Identification:

15 Install hose clamps (37k).

Ensure that dimension (a), measured on the inside, is not exceeded or fallen below.