Actuator Outer Hinge — Removing, Replacing Protective Boot, and Installing

To perform the work, you will need: special pliers for installing clamps for fastening CV joints or sliding pliers; puller of external locking rings; grease for CV joints - 40 cm³; new hinge cover with new clamps; new thrust and retaining rings of the hinge.

Removing

1. Remove the drive assembly (see above, «Front wheel drive - removal and installation»).

2. The ends of all four collars of the inner and outer hinges on both shafts are directed in the direction opposite to the rotation of the drives when moving forward. To ensure correct assembly, if the clamps are to be reused, mark them with a marker to indicate the direction of rotation.

3. With large sliding pliers or special tongs, we compress the large clamp and, using a slotted screwdriver, disconnect the clamp lock.



4. In the same way, remove the small collar of the protective cover of the outer hinge.




5. Using a slotted screwdriver, pry off and remove the protective cover from the outer hinge housing.

Recommendation. A damaged cover can be removed by cutting it with a knife.

Warning! When performing the following operation, if the hinge is to be used repeatedly, do not hit the separator or the hinge body.

6. We fix the drive shaft in a vice. Striking the inner race of the hinge through a soft metal drift, we compress the outer hinge from the drive shaft.



7. Using a slotted screwdriver, pry off and remove the retaining ring from the splines of the drive shaft.



8. Using an external circlip plier, remove the thrust ring.




9. Remove the protective cover from the drive shaft.

10. We wash the hinge in kerosene, wipe it with a clean cloth and let it dry.

Installation

1. In order not to damage the new cover during installation, we wrap the splines of the shaft with adhesive tape or insulating tape.

2. We put a new protective cover on the shaft, move it to the center of the shaft and remove the adhesive tape.

Recommendation. Do not use a socket head to install the thrust ring. The internal chamfer, which has® on almost all heads, will compress the ring, which will not allow it to be installed on the shaft.

3. We fix the drive shaft in a vice vertically. Using a 24 mm open-end wrench as a mandrel, install a thrust ring on the splined end of the shaft.




4. Install the retaining ring in the same way.

5. Lubricate the shaft splines with grease for CV joints.

6. Install the hinge on the splined end of the shaft. We press the hinge onto the shaft through a wooden block until it is fixed with a retaining ring.

Warning! The outer hinge requires 40 cm³ of grease.

7. Fill the hinge with grease for constant velocity joints. The remaining part (from 40 cm³) lubricants are placed in a protective cover.



8. We shift the protective cover towards the hinge so that the large sealing belt of the protective cover is completely put on the hinge body, and the small sealing belt fits into the groove of the shaft.




9. Lifting the sealing belt of small diameter with a slotted screwdriver, we release air from the internal cavity of the cover.



10. Using large sliding pliers or special pliers for installing clamps and a slotted screwdriver, install the large and small clamps of the protective cover. Clamps are installed taking into account the direction of rotation of the drive. The outer end of the clamps must point in the direction opposite to the forward rotation of the drive.

Recommendation. Before installing the assembled drive to the vehicle, be sure to install a new retaining ring on the splined shank of the inner joint.

11. Install the drive assembly on the car (see «Front wheel drive - removal and installation»).