2. Cut the fastening clamps of the protective cover and slide the cover towards the outer CV joint.
3. Remove as much grease from the CV joint as possible and determine the CV joint type.
Ball joint (AC 1700)
1. Using special pliers, loosen the inner CV joint retaining ring. At the same time, tap the open surface of the joint cage with a mallet to separate the CV joint from the drive shaft. Remove the protective cover and rubber rim.
2. Clean the CV joint using kerosene or a suitable solvent and dry it. Inspect the CV joint.
3. Move the CV joint cage from side to side to access each ball (from above) one at a time. Inspect the balls for cracks, flat spots, and pitting.
4. Inspect the ball tracks on the CV joint housing and cage. If the tracks have become wider, the balls will no longer sit tightly in them. Check the CV joint separator slots for signs of wear and cracks.
5. If any of the CV joint components are worn or damaged, the entire drive shaft assembly must be replaced, as none of the components are sold separately. If the CV joint is in good condition, purchase a repair kit of parts, which consists of a new protective boot, rubber flange, retaining spring, and grease.
6. Wrap the grooves on the end of the drive shaft with adhesive tape, then install the rubber flange and protective boot onto the shaft. Attach the inner end of the boot with the flange.
7. Remove the tape, then install the CV joint on the drive shaft (the internal retaining ring must fit into the groove of the shaft).
8. Make sure the snap ring holds the CV joint securely on the drive shaft, then fill the joint with grease. Make sure the grease gets into all the ball tracks and place the excess grease in the protective boot.
9. Place the outer sealing lip of the protective boot into the groove on the CV joint housing. Lift the boot lip to equalize the air pressure. Install the clamps on the boot and tighten them.
10. Make sure the CV joint moves freely in all directions, then install the drive shaft as described in Section Removal and installation the drive shaft.
CV joint with crosspiece (GE86)
1. Remove the inner CV joint, bearing and protective boot as described in Section Replacing the protective boot of the inner CV joint of the right drive shaft (models with manual transmission) or Replacing the protective cover of the inner CV joint of the left drive shaft (models with manual transmission) this Chapter.
2. Where the vibration damper is installed, mark its orientation as well as its position on the drive shaft, then use a puller or press to remove it from the inner end of the drive shaft (refer to the accompanying illustration). Make sure that the puller feet only touch the inner rubber bushing of the vibration damper, otherwise the vibration damper will be distorted.
3. Remove the outer CV joint boot from the inner end of the drive shaft.
4. Clean the outer CV joint using kerosene or a suitable solvent and dry it. Inspect the CV joint.
5. Check the drive shaft crosspiece and the pivot joint for signs of wear, pitting, and abrasions. Make sure the pivot joint turns easily and smoothly, without jerking.
6. If wear or damage is detected, replace the drive shaft, as none of the components are sold separately. If the condition of the CV joint components is satisfactory, purchase a repair kit of parts consisting of a new protective cover, mounting clamps and grease (refer to the accompanying illustration).
7. Wrap the grooves on the inner end of the drive shaft with adhesive tape, then carefully place the outer protective boot onto the shaft.
8. Fill the CV joint with grease (refer to the accompanying illustration) and place the excess in a protective case.
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9. Cover the CV joint with a boot and make sure that its sealing edges fit into the grooves of the drive shaft and the semi-joint (refer to the accompanying illustration). Make sure the CV joint moves freely in all directions.
10. Wet the drive shaft with soapy water. Install the vibration damper on the shaft using a hollow drift that should only rest against its inner sleeve. Use the marks made before removal.
11. Install the inner CV joint components as described in Section Replacing the protective boot of the inner CV joint of the right drive shaft (models with manual transmission) or Replacing the protective cover of the inner CV joint of the left drive shaft (models with manual transmission), then install the drive shaft (refer to Section Removal and installation the drive shaft).