Elements of drive shafts
1 - wheel hub nut; 2 - end pin of the shaft from the side of the wheel; 3 - hinge shell; 4 - sealing cuff of the hinge from the side of the wheel; 5 - drive shaft; 6 - sealing cuff of the hinge from the side of the wheel; 7 - hinge shell; 8 - hinge sprocket; 9 - damper assembly; 10 - spacer pins.
The figure shows the RC 490 hinge (A and C), located on the side of the gearbox, as well as the GE76 / GE86 joint (B), located on the side of the wheel.
1 - hinge shell with axle neck; 2 - drive shaft; 3 - hinged sprocket; 4 - thermal insulation ring or steel sealing cuff; 5 - sealing cuff of the hinge.
By stretching or compressing the individual hinges, the following spacing between the end of the sealing collar and the butt of the hinge must be set:
- A - 155.5-157.5 mm (hinge RC 490);
- B - 152.5-154.5 mm (hinge Gl 62).
On the hinge Gl 69 between the connection, the sealing collar - ball bearing to the end of the shaft (C) there must be an interval of 148.5 mm. A ball bearing fitted with an O-ring can only be compressed with a suitable tube (2). To do this, use the groove (1) as a support for fixing with the appropriate vise jaws, in order to avoid damage to the hinge.
The figure shows special tongs, with the help of which the tape clamp is tensioned by creating a loop on it.
Left: Shown here is a support that folds the lip of the sealing lip restrictor plate onto a Gl-62 hinge using a bronze mandrel. The thickness of the support should be 2.5 mm. Further measurements:
- R - radius 45 mm;
- H - height 6 mm;
- L - length 40 mm.
Right: After the limit plate (1) installed in the required position, the support is removed from the shell of the hinge (2).
Depending on the type of engine installed on your Renault 19, the dimensions of the axle shafts are somewhat different, but they have the same principle of operation. The drive shaft joints are protected by rubber cuffs from moisture and dirt, and from the side of the wheel they are filled with an accurately calculated amount (hinge GE 76 = 180 g; GE 86 = 295 g) high quality lithium grease with molybdenum disulphide (Renault recommendations = MOBIL CVJ 825, MOBIL EXF 570 or Black Star). On the gearbox side, the joints are filled with a lubricant of the same specification (hinge Gl 62 = 130 g; RC 490 = 160 g). The appropriate amount of grease is included with the repair kit.
1. Raise the machine at the front and secure so that the front wheels hang freely.
2. Turn each wheel by hand and check both shaft seals for the respective shaft for small cracks or brittle spots.
3. Are the tie straps firmly attached?
4. Traces of grease on the sealing collar are a danger signal, since an insufficient amount of grease or dirt or moisture that has got inside destroys the hinge very quickly.
5. Replace damaged seals immediately. To do this, the drive shaft must be disconnected from the corresponding drive joint.
Replacement of a sealing cuff of the hinge of a drive
Wheel side
1. Remove the drive shaft.
2. Remove the drive shaft seal from the gearbox side.
3. Tighten the shaft with the butt of the shaft axle located on the side of the wheel into a vise with protective jaws.
4. Carefully cut the tie straps with a knife or hacksaw. When doing this, make sure that the hinge shell groove is not damaged.
5. Using wire cutters or a knife, cut through the damaged hinge seal.
6. Remove the old grease layer and check if it contains dirt particles.
7. If the old grease contains a lot of dirt, thoroughly clean the hinge (do not use any solvents) and check for wear. Hinge, if necessary, replace.
8. Apply the grease supplied with the repair kit to the hinge shell and to the hinge.
9. Put on a new sealing cuff and pay attention to the fact that the bevels of the rubber sit correctly in the grooves of the axle shaft and the hinge shell.
10. Remember the sealing collar a little with your hands and move the hinge to evenly distribute the lubricant.
11. Squeeze the sealing collar and lift the end of the collar to remove excess air. The sealing collar is now installed correctly.
12. Install new tie straps.
13. Using wire cutters - special tongs are used for this in the auto repair shop - make a loop again, as already described, and finally tighten the tie straps.
14. Carry out further work as described for dismantling.
15. Remove the drive shaft.
Replacing the sealing cuff of the drive shaft
Gearbox side
1. Hinge type RC 490: press out 3 bends on the sheet steel sealing collar with a pipe or pliers and turn the thermal insulation ring (depending on version) using a hammer and punch down towards the joint seal.
2. Hinge type Gl 62: use a screwdriver to separate the snap ring from the hinge shell.
3. Both types of hinges: Separate the rubber circlip from the drive shaft using wire cutters.
4. Use wire cutters or a knife to cut the damaged sealing collar.
5. Hinge type RC 490: remove the hinge shell.
6. Hinge type Gl 62: using a gas wrench, bend the safety plate and remove the hinge shell.
7. Take care that the rollers do not slip out of the bearing journals. All details (rollers, bearings and needles) fitted and lapped to each other, so they cannot be interchanged. To fix the parts, the hinge must be wrapped with adhesive tape.
8. Both types of hinges: remove the old grease and check for dirt in it.
9. If the old grease is contaminated, clean the hinge (do not use solvents and set the degree of wear. Replace hinge if necessary.
10. Remove the thrust ring, if any, using pliers and press the drive shaft hinge.
11. When assembling, put the sealing collar with a rubber stop ring on the drive shaft. The applied lubricant will make donning easier.
12. Hinge type RC 490: Depending on the version of the hinge, put on a sheet steel sealing collar or a heat-insulating ring with a metal thrust ring.
13. Both types of joints: insert the joint into the gearing of the drive shaft and press it onto the shaft.
14. Put on the fastening ring, if any, or fix the hinge with 3 strikes of the center punch (every 120°).
15. Distribute the required amount of lubricant over the sealing collar.
16. Hinge type RC 490: install the lubricated shell on the hinge.
17. Insert the sealing collar of the joint with the thrust metal ring into the sheet steel collar or into the thermal insulation ring (depending on execution).
18. Push the sealing collar made of sheet steel or, respectively, the thermal insulation ring up to the stop on the hinge shell and fix it on the steel collar using a rounded mandrel 3 of the packing.
19. Connect the hinge elements so that the distance between the beginning of the sealing collar and the end surface of the hinge shell is from 155 to 157 mm.
20. To equalize the air pressure on the installed rubber cuff, carefully pry it off the drive shaft with a screwdriver.
21. Install the tie strap on the drive shaft and tighten it by squeezing or making a loop, using wire cutters or special tongs.
22. Hinge type Gl 62: slide the adjacent plate.
23. Slide the retaining plate between the hinge shell and the safety plate.
24. Using a mandrel, bead the safety plate along the adjacent plate.
25. Remove the adjacent plate.
26. Slide the joint seal into the slots in the drive shaft and joint shell.
27. Connect the hinge elements so that the distance between the beginning of the sealing collar and the end surface of the hinge shell is from 152.5 to 154.5 mm.
28. To equalize the air pressure on the installed rubber cuff, carefully pry it off the drive shaft with a screwdriver.
29. Fix a sealing cuff of the hinge a spring ring and rubber rings.
30. Perform subsequent work in accordance with the description of disassembly.