Attention! Replace hinge covers immediately at the first sign of damage (even with pinpoint punctures, which are diagnosed by the protrusion of lubricant on the surface of the cover). In many cases, even flushing the hinge and changing the lubricant in it will avoid replacing an expensive assembly.
Only internal hinges can be repaired by replacing parts. If the external hinges fail, they will have to be replaced completely together with the drive shaft, since the shaft is made in one piece with the hinge cage. In operation, the outer hinges can be replaced (with lubricant change) covers only.
To repair the hinges, you will need: a puller to remove the retaining rings or round-nose pliers with thin jaws bent at an angle of 90°, pliers with thin jaws, side cutters or a hacksaw for removing the clamps for fastening covers, beards, hammer, screwdriver with a flat blade.
To repair the left front wheel drive inner joint, do the following.
1. Remove the circlip of the pivot hub by unclenching it with a circlip remover or round nose pliers and removing the circlip from the shaft groove.
2. Slide the hub with rollers along the splines of the shaft...
3.... and remove the hub from the shaft.
Attention! Mark the position of the hub relative to the shaft and, when reassembling, install it according to the marks. If installing a new hub, orient it according to the marks on the old hub.
4. Remove the cover clamp with pliers...
Note. The clamp for attaching the cover can (and much easier) remove by biting it with side cutters, since the hinge repair kit necessarily includes a new clamp.
5.... and remove the cover from the drive shaft along with its holder.
6. If necessary, replace the oil seal (in case of oil leakage from the gearbox) knock off the shaft with hammer blows through the beard of the boot bearing assembly together with the oil seal and mud deflector.
7. Using a suitable mandrel (it can be made from a pipe) press a new bearing assembly onto the shaft, maintaining the dimension (118±0,2) mm between the ends of the shaft and the bearing.
Attention! Be careful when pressing on the bearing assembly. In order not to damage the bearing and seal, press the bearing assembly onto the shaft with a press, not with hammer blows.
8. Install the cover on the shaft, secure it with a clamp, press the hinge hub assembly with rollers onto the splines of the shaft (as a mandrel, you can use a suitable head from the tool kit), matching the marks made during disassembly, and install the retaining ring (see point 1).
To repair the right front wheel drive inner joint, do the following.
1. Remove the dirt washer from the shank of the pivot housing.
2. Remove the large clamp securing the cover by bending its antennae with a screwdriver...
3.... and grabbing the clamp with pliers with thin jaws.
Note. To facilitate the removal of the clamp, you can cut it with a hacksaw, since a new clamp is also included in the hinge repair kit. When sawing the clamp, be careful not to damage the edges of the groove for the cover on the hinge body.
4. Similarly remove a small collar of fastening of a cover.
5. Remove the hinge housing.
6. Remove the spacer spring from the housing...
7....together with thrust washer.
Note. Replace deformed spring...
Note....and a puck.
8. Remove the circlip of the pivot hub by unclenching it with a circlip remover or round nose pliers and removing the circlip from the shaft groove.
9. Slide the hub with rollers along the splines of the shaft...
10.... and remove the hub from the shaft.
Attention! Mark the position of the hub relative to the shaft and, when reassembling, install it according to the marks. If installing a new hub, orient it according to the marks on the old hub.
11. Remove the cover from the drive shaft.
12. If the hinge was disassembled only to replace the boot, remove the old grease from it by washing the inner cavity of the hinge housing with kerosene or gasoline...
13.... and a hub. Dry parts with compressed air.
14. Install a new cover on the drive shaft. Make sure that the annular protrusion on the inner surface of the cover in the region of the small diameter belt falls into the groove on the shaft.
Note. To facilitate installation of the boot on the shaft, lubricate the shaft with a thin layer of lubricant designed to fill the hinge.
15. Press the hinge hub assembly with rollers onto the splines of the shaft (as a mandrel, you can use a suitable head from the tool kit), matching the marks made during disassembly, and install the retaining ring (see point 8).
16. Fill the case with half of the required amount of MOBIL CVJ 825 BLACK STAR grease, the total amount of grease is (124±10) d. Put the rest of the grease evenly into the cavity of the hinge housing.
Attention! Do not reduce or increase the recommended amount of grease in the joint.
17. Install the spacer spring and thrust washer into the cavity of the hinge housing (see paragraphs. 6 and 7).
18. Install the hinge body on the rollers of the three-stud hub and put the hinge cover on the body. Make sure that the annular protrusion on the inner surface of the cover in the region of the large diameter belt falls into the groove on the hinge body.
19. Remove excess air from the cover, for which lift the large edge of the cover and insert a round rod under it, such as a beard.
20. Without removing the rod from under the edge of the cover, move the parts of the hinge so that a distance of 190 mm is established between the ends of the small belt of the cover and the shank of the hinge body.
Note. If you do not remove excess air from under the cover and do not set the required length of the hinge before fixing the cover with clamps, the cover may be damaged during operation.
21. Without changing the position of the parts of the hinge, remove the rod from under the edge of the cover and secure the cover with clamps.
22. Install a dirt washer on the shank of the pivot housing.
To replace the outer hinge boots of both drives, do the following.
1. Remove the internal joints and their covers from the drive shafts. In addition, when replacing the left front wheel drive boot, press the boot bearing assembly with the oil seal and mud deflector off the shaft, as described above in this subsection.
2. When replacing the cover of the outer joint of the drive of the right front wheel, additionally remove the dynamic damper from the drive shaft, overcoming the elastic resistance of the rubber massif of the damper.
Attention! Before removing the dynamic damper, measure and remember the distance between the ends of the damper and the hinge boot so that the damper can be returned to its original position during reassembly.
3. Take off the big...
4.... and small clamps for fastening the cover with a screwdriver, pliers (as described above in this subsection for disassembling the internal hinges) or sawed with a hacksaw for metal.
Note. Damage to the clamps when removing the cover is permissible, since the hinge repair kit necessarily includes new clamps. When sawing the clamps, be careful not to damage the edges of the grooves for the cover on the hinge housing and on the drive shaft.
5. Remove the boot by pulling it over the drive shaft.
Note. To facilitate removal of a damaged boot from the shaft, cut it with scissors or a knife.
Attention! To avoid damage to the hinge in operation, after removing the boot, do not separate the hinge housing and the drive shaft.
6. Remove old grease from the hinge by washing its cavity with gasoline or kerosene, and dry the hinge with compressed air.
Attention! Do not use solvents to clean the hinge.
7. Install a new boot on the drive shaft. Make sure that the annular protrusion on the inner surface of the cover in the region of the small diameter belt falls into the groove on the shaft.
Note. To facilitate pulling the cover along the drive shaft and prevent contamination of the hinge cavity, carefully clean the shaft from dirt and rust with fine-grained sandpaper and lubricate with a thin layer of grease designed to fill the hinge.
8. Fill the case with half of the required amount of MOBIL CVJ 825 BLACK STAR grease, the total amount of grease is (294±10) d. Put the rest of the grease evenly into the cavity of the hinge housing.
Attention! Do not reduce or increase the recommended amount of grease in the joint.
9. Slide the hinge boot over the body. Make sure that the annular protrusion on the inner surface of the cover in the region of the large diameter belt falls into the groove on the hinge body.
10. Remove excess air from the case by lifting the large edge of the case and inserting a round rod under it, such as a beard.
Note. If excess air is not removed from under the case, the case may be damaged during operation.
11. Remove the rod from under the edge of the cover and secure the cover with clamps.
12. To drive the right front wheel, install a dynamic damper on the drive shaft, keeping the distance measured before disassembly between the damper and the hinge cover.
Note. Install the dynamic damper on the shaft, orienting it with its end without shoulder towards the outer hinge.
13. Establish on a drive shaft all details of the internal hinge and its cover as it is described above in this subsection.
Note. To increase the service life of the right front wheel drive inner joint, replace the grease in it with fresh grease for preventive purposes.