Installing the Inner CV Joint

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

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

-- Press on joint until stop.

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

-- Install circlip.

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-- Check circlip for correct seating.

-- Add half of the drive axle grease into the joint on the boot side before installing the joint protective boot.

-- Lubricate the contact surface on the cover.

-- Apply sealant - hatched surface - to clean surface on inner side of protective joint boot cap.

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-- Apply 2 - 3 mm diameter unbroken bead of sealant.

-- The inner sealant bead runs near the holes -arrow-.

-- Use sealant. Refer to the Parts information.

• Protective boot and cap contact surfaces must be free of grease!

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

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-- Drive cover on with a plastic hammer.

-- Clear away leaking sealing immediately.

-- Apply the rest of the drive axle grease through the ball paths into the CV joint.

-- Remove any grease on the cover contact surface and on the CV joint.

-- Apply sealant - hatched area- to the clean surface in the inside of the cover.

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-- Apply 2 - 3 mm diameter unbroken bead of sealant.

-- The inner sealant bead runs near the holes -arrow-.

-- Use sealant. Refer to the Parts information.

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

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It must be aligned exactly because it cannot be aligned after driving on.

-- Drive cover on with a plastic hammer.

-- Clear away leaking sealing immediately.

Joints and protective joint boots must be free of grease.

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-- Position the joint protective boot between the -arrows- into the groove -2-.

1 - Ignore

2 - Positioning groove, push the joint protective boot into the groove until it engages.