Inner CV Joint, Installing

Fig 1: Apply Grease

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-- Slide the CV boot with the "small" clamp onto the drive axle.

-- Before installing the joint, the splines -arrow A- must be lightly coated with grease used in the joint.

-- Arrange the special tools as shown.

Fig 2: Identifying Tools To Press On Inner Constant Velocity Joint

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The :40-204A and clamping surfaces on drive axle must be free of grease.
The chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.

-- Press on joint until it stops.

-- Install the new circlip using the locking ring pliers.

Fig 3: Opening Clamps And Pulling Off CV Joint Boot From Inner Joint

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-- Check the seating of the circlip.

-- Apply half of the enclosed drive axle grease to the joint on the boot side before installing the CV boot.

-- Grease the contact surfaces for the CV boot and cap.

-- Apply Sealant :D 454 300 A2 -cross-hatched surface- on the clean surfaces on the inside of the CV boot cap.

Fig 4: Apply Sealant

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-- Apply the inner sealant bead near the holes -arrow-.

-- Align the cap with bolts -arrows- with the bolt holes.

Fig 5: Aligning Cap With Bolts With Bolt Holes

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NOTE:

It must be aligned exactly because it cannot be aligned after installing.

-- Drive the cap on with a plastic mallet.

-- Remove any excess sealant immediately.

-- Apply the remaining drive axle grease through the ball races in the CV joint.

-- Degrease the contact surfaces for the cover and for the CV joint.

-- Apply Sealant :D 454 300 A2 -cross-hatched surface- on the clean surface on the inside of the cover.

Fig 6: Apply Sealant

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-- Apply the inner sealant bead near the holes -arrow-.

-- Align the new cover with bolts -arrows- to the bolt holes.

Fig 7: Aligning New Cover With Bolts To Screw Holes

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NOTE:

It must be aligned exactly because it cannot be aligned after installing.

-- Drive cover on with a plastic mallet.

-- Clear away leaking sealing immediately.

-- Push on the CV boot and position it in the groove -2- between the -arrows- on the drive axle.

Fig 8: Circlip

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NOTE:

Ignore item -1-.

-- Tighten clamps on inner joint. Refer to Figure.