Detach/attach cup seal from/to joint ring - AR35.30-P-0661-01PF

REAR AXLE SHAFT

Number	Designation			Model 203.018/065/218 / 265/718
BF35.30-P-1001-01D	Filling capacity	Inner constant velocity joint	g	120
BF35.30-P-1002-01D	Filling capacity	Outer constant velocity joint	g	120

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1011-02A	Clamping pliers

Remove cup seal

Clamp rear axle shaft in vice using protective jaws.
Using a hand hacksaw, cut into cup seal (37i) at an angle of approx. 45° to form an angled notch.
Avoid damaging the joint ring (37c).

Fig 1: Cutting Into Cup Seal At An Angle Of Approximately 45 Degrees
Use a screwdriver to lift the notched area.
Starting at raised end, use suitable pliers to twist on cup seal (37i) until it is possible to lift cup seal (37i) from joint ring.
When twisting on cup seal (37i), make sure that rear axle shaft does not drop out of joint ring before positions of components relative to each other have been marked.
Remove hose clamps (37k).
Pull boot with cup seal (37i) off joint ring (37c) and slide down rear axle shaft.
If both boots are being replaced, the opposite boot can be slid over the propeller shaft.

Install cup seal.

Replace O-ring on joint ring (37c).
Do not oil or grease O-ring as this might cause cup seal (37i) to turn on joint ring (37c).

Fig 2: Removing Boot And Clamp
Position cup seal (37i) and slide onto joint ring (37c) as far as it will go. If necessary, drive fully home by tapping gently with a plastic mallet.
Apply four blows at 90° intervals to seat cup seal (37i) in groove running around circumference of joint ring.

Fig 3: Locating Cup Seal, Joint Ring And Plastic Mallet
Apply even blows with a suitable hammer to drive cup seal (37i) into groove running around circumference of joint ring.
Ensure that cup seal (37i) is fitted correctly.

Fig 4: Driving The Cap Seal Into The Groove Extending Along The Periphery Of The Joint Ring
Continue to apply peen and use even blows of plastic mallet to drive cup seal (37i) firmly into groove.

Fig 5: Driving The Cap Seal Firmly Into The Groove
Fill joint with new grease.
Slide boot (37l) onto cup seal.
To prevent leaks, ensure that sealing bead (arrow) on boot (37l) is resting between sealing beads on cup seal (37i).

After boot (37l) is slid on, no grooves on rear axle shaft should be visible at end with smaller diameter. This indicates that raised bead on boot (37l) is in first groove.

Fig 6: Locating Slide Boot And Cap Seal
Install hose clamps (37k).

To ensure a secure fit, make sure that dimension "a" is not over-ranged or under-ranged.

Fig 7: Installing Hose Clamps