31 60 535 Replacing Both Gaiters of Output Shaft on Left or Right

31 60 535 Replacing Both Gaiters Of Output Shaft On Left Or Right (Cooper S, Diesel And All Automatic Transmissions)

Special tools required:







NOTE: Output shaft removed.







IMPORTANT:
Repair may only be carried out via the inner joint. Do not press off or disassemble wheel-side joint.
The transmission-side joint may be bent by max. 18° and the wheel-side joint by max. 451
Remove all traces of old grease from inner joint, wipe off old grease from outer joint.
Only use dry, clean cloth free of grease and lint for cleaning.
Visible soiling of joints (e.g. by water or dirt) will cause premature failure.







IMPORTANT:
Always use plastic vice jaw protectors when working with a vice.
Do not use previously used clamping bands.

Clean output shaft and grip in vice.
Release clamping bands (1).
Detach housing (2) and clean carefully.







Remove circlip (1).







Pull off tripod star (1) from output shaft with special tool 11 8 310 and clean carefully.







IMPORTANT: Remove all traces of old grease. Old gaiter must not be reused.

Detach gaiter (1) of joint on transmission side and carefully clean output shaft.







Manual gearbox only:
Press vibration absorber (1), if fitted, off output shaft (2) with press.
Vibration absorber must not be reused.
Replace vibration absorber. Follow procedure.







Removing outer joint gaiter:

IMPORTANT:
The wheel-side constant velocity joint is pressed on and secured with a snap ring. Do not press off or disassemble.
Failure to comply with this instruction will result in the constant velocity joint being damaged.

Mark axial position (1) of gaiter (2) to wheel-side joint (4).
Release clamping bands (3).
Detach gaiter (2) of joint on wheel side.
Wipe accessible areas of joint (4) with a clean and lint-free cloth.







Installing outer joint gaiter:

IMPORTANT:
The joint on the wheel side must not be packed with more than 80 g of grease.
Only use grease from the repair kit or as specified in the Electronic Parts Catalogue.
During assembly, the sealing surfaces on the gaiter and joint must be clean, dry and free of grease.







Slide new gaiter (1) onto output shaft and pack with lubricating grease.

NOTE: The sealing surfaces (2) inside the gaiter and the groove on the constant velocity joint must be dry, clean and free of grease







Push packed gaiter together with infinitely variable jubilee clip - 92.0 mm on to joint on wheel side.
Ensure the gaiter snaps into the groove in the joint and is aligned with the axial marks.
Align gaiter to shaft shoulder with dimension (A) = 4 mm.

Position a new infinitely variable jubilee clip 92 mm in the gaiter groove and close with special tool 32 1 260.

NOTE: The diameters of the stepless ear clips are marked on the components.







IMPORTANT: Gaiter must be bled after fitting in order to adapt the excess pressure generated during fitting to the ambient pressure.

Bleed gaiter; carefully slide a suitable tool between gaiter and output shaft for this purpose.

NOTE: Make sure gaiter is correctly seated in groove of output shaft.







Close new infinitely variable jubilee clip (1) dia.33.5 mm with special tool 32 1 260.







Manual gearbox only:
Even if no vibration absorber was mounted on the shaft, the new vibration absorber must still be installed.
Push back vibration absorber to shaft shoulder (1) on inner joint (note following operation).







Pressing on vibration absorber:
Coat vibration absorber and output shaft with Tip Top tyre-fitting paste (BMW part no. 81 22 9 407 288).
Grip output shaft in vice (aluminium clamps) and push vibration absorber (1) by hand onto output shaft.

IMPORTANT: Aerate for at least 4 hours prior to returning to customer.







Installing inner joint gaiter:
Slide new gaiter (1) together with infinitely variable jubilee clip - 34.6 mm onto output shaft.

Installation note:
In vehicles with an automatic transmission, slide gaiter of transmission-side joint to the stop of the wheel-side gaiter, and in vehicles with a manual transmission, to the vibration absorber.







IMPORTANT: Align tripod star so that phase (arrow) points towards output shaft.

Drive tripod star with special tool 00 5 500 onto output shaft until groove for circlip is exposed.







Install new copper coloured circlip (1).







IMPORTANT:
Packing of grease in the transmission-side joint must not exceed 130 g.
Only use grease from the repair kit or as specified in the Electronic Parts Catalogue.

Pack lubricating grease into housing (1).







IMPORTANT: During assembly, the sealing surfaces on the gaiter and joint must be clean, dry and free of grease.

Attach packed housing (1) to tripod star and into gaiter (2).

NOTE: Make sure gaiter is correctly seated in groove in housing.







IMPORTANT:
The centre point of clip must be level with the centre line of the housing.
Max. deviation (A) ± 10 mm

Close new infinitely variable retaining clip 89.5 mm with special tool 31 5 200.







IMPORTANT:
The stepless tensioning strap must snap into place completely with both hooks. Both hooks must no longer be visible after engagement.
The closing travel is 13 mm







Adjust gaiter (1) with housing to an installation length of 100 mm.

IMPORTANT: Gaiter must be bled after fitting in order to adapt the excess pressure generated during fitting to the ambient pressure.

Vent gaiter (1); carefully slide a suitable tool between gaiter and output shaft for this purpose.
Close new infinitely variable jubilee clip (2) dia.34.6 mm with special tool 32 1 260.







Renew transmission circlip:

IMPORTANT: Service kit contains two circlips for different transmission versions. The ring for the automatic transmission is marked with label "A". Check for correctness before installing the circlip.







IMPORTANT:
The circlips shown in the cross-section (mm) must not exceed the maximum outer diameters specified below after installation.
M - Manual transmission
A - Automatic transmission