7.9
FINAL DRIVE
7
IMPORTANT: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint should
be replaced.
7. Thoroughly clean the joint with an appropriate solvent and
dry the joint to prevent any residual solvent from being left
in the joint upon reassembly.
8. Visually inspect the joint by tilting the inner race to one side
to expose each ball. Severe pitting, galling, play between
the ball and its cage window, any cracking or damage to the
cage, pitting or galling or chips in raceways call for joint
replacement.
NOTE: Shiny areas in ball tracks and on the cage
spheres are normal. Do not replace CV joints
because parts have polished surfaces. Replace CV
joint only if components are cracked, broken, worn
or otherwise unserviceable.
9. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
10. Slide the small boot clamp and boot (small end first) onto
the drive shaft and position the boot in it’s groove machined
in the shaft.
11. Install a NEW circlip on the end of the shaft.
12. Grease the joint with the special CV joint grease provided
in the boot replacement kit. Fill the cavity behind the balls
and the splined hole in the joint’s inner race. Pack the ball
tracks and outer face flush with grease. Place any
remaining grease into the boot.
NOTE: The amount of grease that’s provided is pre-
measured, so use all the grease.
13. Slide the joint onto the drive shaft splines and align the
circlip with the lead-in chamfer on the inner race of the
joint.
14. Use a soft-faced hammer to tap the joint onto the drive shaft
until it locks into place.
15. Pull on the joint to make sure it is securely locked into place.
16. Remove excess grease from the CV joint’s external
surfaces and place the excess grease in the boot.
17. Pull the boot over the joint and position the boot lips into
the grooves on the joint housing and shaft. Make sure the
boot is not dimpled or collapsed.
18. Install and secure the CV boot with the large clamp using
the “earless” clamp pliers.
19. While pulling out on the CV shaft, fully extend the CV joint
and slide a straight O-ring pick or a small slotted screw
driver between the small end of the boot and the shaft. This
will allow the air pressure to equalize in the CV boot in the
position that the joint will spend most of its life. Before you
remove your instrument, be sure the small end of the boot
is in its correct location on the shaft.
20. Install and secure the small clamp on the boot using the
“earless” clamp pliers.
CAUTION
The grease provided in the replacement kit is
specially formulated for wear resistance and
durability. DO NOT use substitutes
or mix with other lubricants.
Boot Replacement Grease Requirement:
Grease Only Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Outer CV Joint Capacity: 150g
CV Boot Clamp Pliers
Earless Type: 8700226
CV Boot Clamp Pliers
Earless Type: 8700226
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