Replacing the bellows of the output shaft

Precondition 

• Output shaft removed  .

Preliminary work 

• Refer to DETERMINING THE MANUFACTURER OF THE OUTPUT SHAFT .
• Refer to INSERTING THE OUTPUT SHAFT .

• Release the clamps (1) and (2), and cut and remove them with the special tool 0 494 152 (32 1 260)  in a transverse direction to the ear.
• Release the bellows (3) on the transmission end in the arrow direction from the joint housing (4).
• Pull the joint housing (4) down in the arrow direction.

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• Release the circlip (1) for the tripod (2) from the output shaft (3).

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• Seal bore of output shaft with a screw (2).
• Pull down tripod (1) using special tool 0 493 994 (11 8 310)  .

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• Remove traces of lubricating grease.
• Pull down the bellows (1) at the transmission end from the output shaft (2).

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• Release the circlips (1) and (2) or cut open across the ear and remove.
• Pull the bellows (3) down in the arrow direction from the wheel-sided constant velocity joint.

• Clean accessible areas of the constant velocity joint (1) and the output shaft (2) with a clean, lint-free cloth.
• Replace bellows.

  Parts:  gaiter

• Slide the bellows onto the output shaft (2).
• Grease the constant velocity joint (1).
  CONSUMABLE SPECIFICATION
  
  

  Lubricating grease, Optitemp 2 LN 584 LO

  100 g, Bag

  83190447919

  Courtesy of BMW OF NORTH AMERICA, INC.

  NOTE: TECHNICAL INFORMATION 
  The bellows must be vented after installation in order to adapt the excess pressure generated during installation to the ambient pressure!

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  • Make sure that the sealing surfaces on the bellows and on the joint are clean, dry and free from grease during installation.
  • Position the bellows (3) on the constant velocity joint.
  • Slide the suitable commercially available tool carefully between the bellows and the output shaft and let the excess pressure in the bellows (3) be released.
  • Replace the circlips (1) and (2).

    Parts:  Clamps

  • Position the circlips (1) and (2).
  NOTE: TECHNICAL INFORMATION 
  Observe the notes on the disassembly and installation of low profile hose clamps and ear hose clamps!
  For additional information see: 31 60... NOTES ON THE DISASSEMBLY AND INSTALLATION OF LOW PROFILE HOSE CLAMPS .
  For additional information see: NOTES ON INSTALLATION OF EAR HOSE CLAMPS .
  • Tighten the circlips (1) and (2) on the bellows (3).

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  • Replace the bellows (1) and the circlips.

    Parts:  Bellows, circlips

  • Slide the circlips onto the output shaft (2).
  • Slide the bellows (1) onto the output shaft (2).

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  • Clean tripod (2).
  • Position the tripod (2) on the output shaft in such a way that the flat side (1) points to the circlip.

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  • Tap the tripod (1) with the standard tool (2) and the commercially available tool (3) only so far onto output shaft until the circlip can be mounted.

    Standard tool: Socket wrench for hexagon head 

    Socket wrench for hexagon 

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    Courtesy of BMW OF NORTH AMERICA, INC.

    Socket wrench for hexagon SW24

    For output shafts of the manufacturer neapco, the dimension (A) must not be exceeded.

    Dimension (A) = 4.9 mm

  • Replace the circlip (1).

    Parts:  Circlip

  • Mount the circlip (1) for the tripod (2) on the output shaft (3).
  • Grease tripod (2) and the joint housing (see table).

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  • The lubricating grease and the quantities in the table must be observed when greasing the wheel sided  joint!

  Part number of bellows	8 680 223	8 488 704	8 657 288
  Part number of lubricating grease	2 286 018	2 179 708	2179708
  Amount of lubricating grease	140 g	165 g	165 g

  CONSUMABLE SPECIFICATION
  
  

  Lubricating grease Renolit CX-TP 1

  100 g, Bag

  83192286018

  CONSUMABLE SPECIFICATION
  
  

  Lubricating grease One Lube Improved

  110g, Bag

  83232179708

  • Slide the joint housing (4) in the arrow direction onto the tripod.
  • Mount the bellows (3) in the arrow direction on the joint housing (4).
  • Position the circlips (1) and (2) on the bellows (3).

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  • Position the bellows (1) for the taper (2) on the output shaft.

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  • Position the hook fastener of the circlip (1) as shown in the center on the joint housing (2).

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  NOTE: TECHNICAL INFORMATION 
  Observe the notes on the disassembly and installation of low profile hose clamps and ear hose clamps!
  For additional information see: 31 60... NOTES ON THE DISASSEMBLY AND INSTALLATION OF LOW PROFILE HOSE CLAMPS .
  For additional information see: NOTES ON INSTALLATION OF EAR HOSE CLAMPS .
• Check the position of the joint housing (4) and the bellows (3), correct if necessary.
• Tighten the circlips (1) and (2).

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