Removal from the left side. 1. Drive shaft; 2. Cotter pin.
Removal from the right side. 1. Cotter pin; 2. Drive shaft; 3. Plate; 4. Support bearing bracket.
Disassembly on the left side. 1. Ring clamp; 2. Dust cover; 3. Body; 4. Retaining ring; 5. Cross assembly; 6. Retaining ring; 7. Case clamp; 8. Case; 9. Shaft; 10. Ring clamp; 11. Hinge assembly.
Disassembly on the right side. 1. Hinge assembly; 2. Ring clamp; 3. Case clamp; 4. Case; 5. Shaft; 6. Dynamic shock absorber clamp; 7. Dynamic shock absorber; 8. Retaining ring; 9. Cross assembly; 10. Retaining ring; 11. Body; 12. Dust cover; 13. Support bearing; 14. Retaining ring; 15. Dust cover.
Removal
On the left side
1. Follow steps 1-11. «Replacement» higher.
2. Remove the drive shaft from the transmission assembly.
- Remove using the attachment (A) to the drive shaft (special tool KV40107500) and impact puller (IN), inserting the tip of the attachment between the housing and the gearbox.
Attention. Do not bend the drive shaft joint to a large angle when removing the drive shaft. Also, do not overextend the sliding joint.
On the right side
1. Follow steps 1-11. «Replacement» higher.
2. Remove the exhaust manifold strut. See chapter «Mechanical part of the engine».
3. Unscrew the plate bolts and remove the plate.
4. If necessary, unscrew the mounting bolts on the support bearing bracket and remove the bracket.
5. Remove the drive shaft from the transmission assembly.
- Remove using the attachment to the drive shaft (special tool: KV40107500) and an impact puller by inserting the tip of the attachment between the housing and the gearbox.
Attention. Do not bend the drive shaft joint to a large angle when removing the drive shaft. Also, do not overextend the sliding joint.
Installation
On the left side
Installation is carried out in the reverse order of removal, taking into account the following:
Attention. When installing the drive shaft, always replace the differential seal. See chapter «Continuously Variable Automatic Transmission (CVT)».
- To avoid damaging the oil seal when installing the drive shaft, install protection (A) (special tool: KV381079000) to the gearbox.
- Insert the sliding joint into the water shaft and install securely by tapping with a hammer.
Attention. Make sure the ring clamp is fully engaged.
On the right side
Installation is carried out in the reverse order of removal, taking into account the following:
Attention. When installing the drive shaft, always notice the differential seal. See chapter «Continuously Variable Automatic Transmission (CVT)».
- To avoid damaging the oil seal when installing the drive shaft, install protection (A) (special tool KV381079000) to the gearbox.
- Insert the drive shaft sliding joint and tap it securely with a hammer.
- When installing the support bearing bracket (1).
Tighten the mounting bolts by hand in order (A), (IN), (WITH).
Tighten the mounting bolts in order (IN), (WITH), (A).
Place the plate (2) so that the cutout (E) ended up on top. Tighten the mounting bolts by hand in order (D), (F).
Attention. Do not reuse the plate.
Disassembly
Transmission side
1. Secure the shaft in a vice.
Attention. When securing the shaft in a vice, protect it from damage by laying aluminum or copper strips.
2. Remove the clips from the case, then remove the case from the body.
3. Remove the retaining ring.
4. Apply alignment marks. onto the housing and shaft, then remove the housing from the shaft.
Attention. Apply marks with paint or similar substance. Do not scratch surfaces.
5. Apply registration marks (A) onto the cross assembly and shaft.
Attention. Apply marks with paint or similar substance. Do not scratch surfaces.
6. Remove the retaining ring (1), then remove the spider assembly from the shaft.
7. Remove the cover from the shaft.
8. Remove the ring clamp from the shaft (on the left side).
9. Remove the dust cover. cover from the body.
10. Remove old grease from the housing with paper towels.
Support bearing
1. Remove the dust cover. cover from the body.
2. Remove the retaining ring.
3. Press the support bearing out of the housing
4. Remove the dust cover.
Dynamic shock absorber
Remove the clamps, then remove the dynamic shock absorber from the shaft.
Wheel side
1. Secure the shaft in a vice.
Attention. When securing the shaft in a vice, protect it from damage by laying aluminum or copper strips.
2. Remove the clamps from the boot and then remove the boot from the hinge assembly.
3. Screw on the drive shaft puller (A) on the threads of the joint assembly by at least 30 mm and remove the joint assembly from the shaft using an impact puller (IN).
Attention:
- If the hinge assembly cannot be removed even after 5 attempts, replace the shaft and hinge assembly as a set.
- Center the impact puller and the drive shaft and remove using force at a straight angle.
4. Remove the ring clamp from the shaft.
5. Remove the cover from the shaft.
6. Remove old grease from the hinge assembly with paper towels while rotating the cage.
Assembly
Transmission side
1. To avoid damaging the cover, wrap the splined part of the shaft with electrical tape (A). Place the new cover on the shaft and secure with clamps.
Attention. Do not reuse the case or clips.
2. Remove the electrical tape wrapped around the splined part of the shaft.
3. Align the marks (A) applied to the shaft (2) when removing the cross (1). Install the cross assembly with the splined part (IN) towards the drive shaft.
4. Secure the spider assembly to the shaft with a retaining ring (1).
Attention. Do not reuse the retaining ring.
5. Apply the required amount of lubricant to the spider assembly and sliding surface.
6. Install the housing onto the cross assembly and add lubricant to the amount specified below.
Standard.
Lubricant quantity: See paragraph below. «Technical data and specifications».
7. Align the marks made when removing the housing.
8. Install the retaining ring.
Attention. Do not reuse the retaining ring.
9. Secure the case tightly into the grooves (marked «*»), as shown in the picture.
Attention. If on the seating surfaces of the cover (marked «*») If grease gets on the shaft or housing, the cover may come off. Remove all grease from surfaces.
10. To avoid deformation of the cover, adjust the installation length of the cover to the required value («L»), below by inserting a flat blade screwdriver or similar tool under the wide side of the boot and releasing the air from it.
Standard.
Cover installation length («L»): See paragraph below. «Technical data and specifications».
Attention:
- If the installation length of the cover is different from the norm, the cover may break.
- Do not touch the tip of the screwdriver to the inside surface of the case.
11. Securely secure the wide and narrow sides of the cover with new clips as shown in the illustration.
Attention. Do not reuse cover clips.
12. Secure the housing and shaft, then make sure that they are in the required position by turning the cover. Otherwise, reinstall them with new boot clips.
13. Install the dust cover (on the left side).
Attention. Do not reuse the dust cover.
14. Install the ring clamp onto the body (on the left side).
Attention. Do not reuse the ring clamp.
Support bearing
1 Install the dust cover on the body.
Attention. Do not reuse the dust cover.
2. Press the support bearing onto the housing.
3. Install the retaining ring.
Attention. Do not reuse the retaining ring.
4. Install dust covers.
Attention. Do not reuse dust covers.
Dynamic shock absorber
If the dynamic shock absorber is removed, secure it with new clamps as shown in the illustration so that the dimensions match those shown below.
Attention. Do not reuse the cover clips.
Standard.
Size: See below item. «Technical data and specifications».
Wheel side
Perform assembly following the steps in paragraph. «Replacing the drive shaft boot» higher.
Check after removal
- Move the joint up/down, left/right and axially. Make sure the movement is smooth and there is no significant play.
- Check for cracks or damage on the covers and for lubricant leaks.
- If there are any abnormalities, remove the drive shaft and replace the faulty components.
Check after disassembly
Shaft
Check for runout, cracks or other damage to the shaft. Replace if necessary.
Dynamic shock absorber
Check for cracks or wear. Replace if necessary.
Hinge assembly (from the wheel side)
Check the following:
- Does the hinge assembly rotate freely and is there excessive movement? axial play.
- Whether foreign particles have entered the hinge assembly.
- Are there any cuts, cracks or breaks inside the hinge assembly?
- If any abnormality is found, replace the hinge assembly.
- Housing and cross assembly (from the gearbox side).
- If there are scratches or wear on the contact surface under the rollers on the body or crosspiece side, replace the body and crosspiece assembly.
Note. The body and cross assembly are replaced as a set.
Support bearing (on the right side)
Make sure the wheel bearing rotates freely. Check for knocking cracks, pitting and wear. If there are any abnormalities, replace the support bearing.
Support bearing bracket (on the right side)
Check for bending, cracks or damage. If there are deviations from the norm, replace the support bearing bracket.