Contents: Inner hinge and its cover ⇓ Outer hinge ⇓
Note 1: If constant velocity joint repair is required (usually due to damage to the protective covers), carefully study all the details of the upcoming work before starting it. It is more convenient to purchase a refurbished hinge instead of repairing it, which will save a lot of time and effort. However, in any case, first find out the cost of spare parts and the possibility of purchasing them, and then begin the repair.
Note 2: Replacement protective boots may be designed to be installed without removing the drive shaft. Purchasing such covers is a temporary measure. It is also advisable to remove the drive shaft to ensure that the constant velocity joint is not contaminated. Otherwise, the hinge will quickly fail.
Note 3: In vehicles equipped with the ABS system, the system sensor rings are installed on the outer hinges. Inspect the rings and make sure they are not damaged. Sweep the rings if necessary.
1. Remove the drive shaft (see paragraph 11).
2. Clamp the drive shaft in a vice, placing wooden shims underneath (to avoid damaging the shaft).
Inner hinge and its cover
Three-finger hinge
Disassembly
3. Remove the cover clamps (figure 13.3, a, b).
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4. Remove the cover from the hinge, then remove the retaining ring and remove the housing from the hinge. Before doing this, mark the position of the hinge relative to the body (figure 13.4).
5. Use a center punch to mark the joint and drive shaft to ensure proper assembly (figure 13.5).
6. Using pliers, remove the retaining ring from the drive shaft (figure 13.6).
7. Using a hammer and a soft metal punch, knock the joint off the drive shaft (figure 13.7).
Examination
8. Remove old grease from the housing and from the hinge. Disassemble each section of the hinge one by one (do not disassemble sections at the same time to avoid mixing up the parts) and wash the bearing needles in solvent.
9. Inspect the bearing needles, axles and outer bearing races for damage or wear. Replace the joint if necessary.
Assembly
10. Wrap the splines of the drive shaft with insulating tape to prevent them from damaging the boot. Place the clamps and boot on the drive shaft (figure 13.10).
11. Install the joint on the drive shaft (so that the marks made before removing the hinge match), then insert the retaining ring. Apply grease to the hinge, the inner surface of the hinge housing and place it in the boot (figure 13.11).
12. Place the cover on the hinge so that its ends fit into the corresponding grooves.
13. Adjust the length of the hinge according to Technical data (Fig. 13.13).
14. Equalize the air pressure inside the case (figure 13.14).
15. Tighten the cover mounting clamps (fig. 13.15, a-d). Go to p. 35.
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Ball joint
Disassembly
16. Remove the cover clamps (see Fig. 13.3,a) and throw them away.
17. Remove the cover from the hinge.
18. Remove the retaining ring from the hinge housing (Fig. 13.18).
19. Remove the housing from the hinge (figure 13.19).
20. Remove the retaining ring from the drive shaft (figure 13.20).
21. Remove the inner link of the joint from the drive shaft.
22. Mark the relative position inside its ring relative to the separator to ensure correct assembly (figure 13.22).
23. Using a screwdriver, remove the balls from the separator. Be careful not to damage the balls, cage, or inner link of the joint. Remove the separator.
Examination
24. Remove old grease and wash all components in solvent. Inspect the separator and rings for signs of pitting, chipping, wear or damage (figure 13.24, a, b). Shiny spots on surfaces are not a sign of their malfunction.
Assembly
25. Wrap the drive shaft splines with insulating tape to prevent them from damaging the boot. Place the clamps and boot on the drive shaft, then remove the insulating tape.
26. Assemble the hinge unit. To do this, place the separator on the inner link. Insert (by hand) the balls into the holes of the separator (figure 13.26).
27. Lubricate the hinge with fresh grease (usually this grease is included with the hinge repair kit).
28. Place the hinge assembly on the drive shaft so that the smaller diameter of the separator is on the inside (figure 13.28).
29. Insert the retaining ring into the shaft groove. Lift the inner hinge link outward to ensure it is securely fastened.
30. Fill the joint housing with grease so that it completely fills the entire housing.
31. Install the bearing retaining ring.
32. Remove excess grease from the groove under the boot on the hinge housing. Place the boot on the drive shaft so that it fits into the groove of the drive shaft. Place the cover over the hinge housing.
33. Insert a small screwdriver between the boot and the hinge housing and equalize the air pressure inside the boot (see figure 13.13). Do not damage the case.
34. Adjust the length of the drive shaft according to Technical data (see figure 13.14).
35. Tighten the cover mounting clamps (see Fig. 13.15, a-d). Proceed to the next item.
For all internal hinges
35. Install a new retaining ring on the inner joint shaft (see figure 11.10, a, b).
36. Install the drive shaft on the vehicle (see paragraph 11).
Outer hinge
37. Remove the cover clamps (see figure 13. H, A, B) and pull the cover back so that you can inspect the hinge.
38. Thoroughly rinse the joint in solvent and dry it with compressed air (if such an opportunity exists). The outer hinge is non-detachable, making it difficult to clean from old grease. However, if you are patient, cleaning the hinge is entirely possible.
39. Turn the joint housing over to see the balls, inner ring and separator. Inspect these components for wear or damage. If necessary, replace the joint together with the drive shaft (figure 13.39).
40. If the outer joint boot is damaged and the joint itself is in good condition, remove the inner joint and the outer joint boot (removal of the three-pin type inner joint is described in paragraphs. 3-9, and removal of the ball-type joint - in paragraphs 18-24). If a dynamic damper is installed on the shaft, mark its position relative to the shaft, then remove the clamp and damper.
41. Place the new outer joint boot onto the drive shaft. To prevent damage to the boot, wrap the end of the drive shaft with electrical tape (see Fig. 13.10). After this, apply fresh grease to the outer hinge and its boot. Put the boot on the hinge, equalize the air pressure in it and secure it with new clamps (see Figure 13.15, a-d). Install a dynamic damper on the drive shaft (if there is one) and secure it with a new clamp, aligning the marks on the shaft and damper (see item 40). Tighten the damper fasteners.
42. Place a smaller diameter clamp and the inner joint cover on the drive shaft and install the inner joint (installation of the three-pin type inner joint is described in paragraphs. 10-15, and installing a ball-type joint - in paragraphs 25-35). Before tightening the clamps securing the inner joint boot, adjust the length of the drive shaft.
43. Install the drive shaft on the vehicle (see paragraph 11).