Removal
- Remove the drive shaft on which the protective cover needs to be replaced
- Cut the clamp that secures the elastic corrugated protective cover to the drive shaft.
- Cut the clamp that secures the elastic corrugated protective cover to the constant velocity joint housing, being careful not to damage the groove on the joint housing.
- Cut the protective cover.
- Remove as much grease as possible.
- Remove the constant velocity joint housing from the drive shaft.
Attention
- The hinge housing is not equipped with a retaining ring, allowing it to be removed without effort.
- When removing the CV joint housing from the drive shaft, be careful not to remove the rollers from the crosspiece.
- Do not use solvents to clean the hinge parts.
- Using special pliers, remove the retaining ring securing the three-axis support of the tripod CV joint rollers.
- Using a press and a special device, push the drive shaft out of the three-axis support of the tripod CV joint rollers.
Installation
- Lubricate the drive shaft and put two clamps and a protective cover on it
- Using a tubular mandrel of the appropriate diameter, install the three-axis support of the tripod CV joint rollers on the drive shaft
- Install the retaining ring for fastening the three-axis support of the tripod CV joint rollers.
- Place the lubricant in the elastic corrugated protective cover and distribute it evenly inside the cover.
- Install the constant velocity joint housing onto the drive shaft.
- Insert a smooth rod with a rounded end between the boot and the drive shaft to release "excess" air from the boot.
- Move the hinge housing along the shaft so as to obtain dimension A = 156±1 mm between the end of the boot and the area of the largest diameter of the machined surface of the hinge housing (fig. 8.9).
- In this position, remove the rod.
- Use special pliers T. Av. 1034 to tighten the small clamp of the protective cover. To tighten the large clamp of the protective cover, use OETIKER pliers.
- Install the drive shaft.
Right Drive Shaft Inner Joint RC 490 - JC Gearbox
Removal
- Use pliers to peal the casing in three places (fig. 8.21).
- Cut the clamp and the elastic corrugated protective cover along its entire length.
- Remove as much grease as possible.
- Remove the casing.
- Remove the constant velocity joint housing from the drive shaft (fig. 8.16).
Attention.
- The hinge housing is not equipped with a retaining ring, allowing it to be removed without effort.
- When removing the CV joint housing from the drive shaft, be careful not to remove the rollers from the crosspiece.
- Using special pliers, remove the retaining ring of the three-axis support of the tripod CV joint rollers (fig. 8.17).
- Using a press and a special device, push the drive shaft out of the three-axis support of the tripod CV joint rollers (fig. 8.18).
Installation
- Lubricate the drive shaft and fit a clamp and elastic corrugated protective cover (2, Fig. 8.22) with a metal insert (3) and a casing (1).
- Using a tubular mandrel of the appropriate diameter, install the three-axis support of the tripod CV joint rollers on the drive shaft (fig. 8.19).
- Install the retaining ring for fastening the three-axis support of the tripod CV joint rollers or caulk at three points every 120°, rolling the metal onto the splines of the drive shaft.
- Place the lubricant in the elastic corrugated protective cover and distribute it evenly inside the cover.
Note: The amount of grease added must strictly correspond to that specified in the chapter "Technical data".
- Install the cover and metal insert into the casing.
- Install the casing by moving it until it touches the flange on the hinge housing.
- In this position, fix the casing on the hinge body by punching in three holes on the casing (fig. 8.23).
- Insert a smooth rod with a rounded end between the boot and the drive shaft to release "excess" air from the boot.
- Move the hinge housing along the shaft so as to obtain dimension A = 156±1 mm between the end of the boot and the area of the largest diameter of the machined surface of the hinge housing (fig. 8.24).
- In this position, remove the rod.
- Use special pliers T. Av. 1034 to tighten the clamp securing the protective cover.
- Install the drive shaft.
Fig. 8.18. Using a press and a special device to squeeze the drive shaft out of the three-axis support of the tripod CV joint rollers
Fig. 8.19. Installation of a three-axis support of tripod CV joint rollers on the drive shaft
Fig. 8.20. Inner joint of the right drive shaft RC 490: 1 - hinge housing; 2 - three-axis roller support; 3 - casing; 4 - protective cover; 5 - clamp; 6 - drive shaft; 7 - metal insert
Fig. 8.21. Using pliers to caulk a constant velocity joint housing
Fig. 8.22. Protective cover (2), insert (3) and casing (1) of the inner CV joint RC 490 of the right drive shaft
Fig. 8.23. Fixing the casing on the constant velocity joint body
Fig. 8.24. Measuring the distance between the end of the cover and the area of the largest diameter of the hinge housing: A = 156±1 mm