Replacing both Bellows on left and right of output shaft (Cooper Convertible)

Special tools required:

00 5 500
11 8 310
31 5 200
32 1 260

NOTE: Output shaft removed.

IMPORTANT: Repair may only be carried out via the inner joint! Do not press off or disassemble wheel-side joint.
The transmission-side joint may be bent by max. 18° and the wheel-side joint by max. 45°!
Remove all traces of old grease from inner joint, wipe off old grease from outer joint!
Only use dry, clean cloth free of grease and lint for cleaning!
Visible soiling of joints (e.g. by water or dirt) will cause premature failure!

The wheel-side bellows may not be replaced with output shafts that have a dynamic damper (1)!

Output shafts with dynamic damper (1) and faulty wheel-side bellows require a complete replaceal of the output shaft.

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IMPORTANT: Always use plastic or aluminum vice jaw protectors when working with a vice!
Luggage straps are not to be reused!

Clean the output shaft (2) and place it into the vice.

(1) = Wheel-side joint

(3) = Joint on transmission end

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IMPORTANT: Check installation position.
Before disassembling the tripod joint, the position of the joint housing (1), tripod joint (2) and output shaft (3) relative to each other must be noted.
The separate components must be reassembled in the same position in relation to each other (marking).

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Detach the band clamps (1) and (2).

Slide the bellows (3) back.

Detach joint housing (4).

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Detach the snap ring (1) for the tripod (2) from the output shaft (3).

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Use a three-claw extractor tool (3) to pull the tripod (1) off the output shaft and clean it carefully.

If necessary, use a suitable bolt (2) to close the bore.

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IMPORTANT: Remove all traces of old grease. Old bellows must not be reused!

Detach bellows (1) of joint on transmission side and carefully clean output shaft.

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Removing outer joint bellows:

IMPORTANT: The wheel-side constant velocity joint is pressed on and secured with a snap ring. Do not press off or disassemble!
Failure to comply with this instruction will result in damage to the constant velocity joint.

Detach the luggage straps (1) and (2).

Detach bellows (3) of joint on wheel side.

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Wipe accessible areas of joint (1) and the output shaft (2) with a clean and lint-free cloth.

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Installing outer joint bellows:

During assembly, the sealing surfaces on the bellows and joint must be clean, dry and free of grease!

It is imperative to follow the grease and quantities listed in the table to top off the grease!

Bellows part number	8 618 537 8 618 538	8 618 547 8 618 548	8 618 539 8 618 540	8 618 541 8 618 542	8 618 545 8 618 546	8 625 846 8 625 847	8 618 551 8 618 552
Joint on the transmission end Grease quantity Grease	125 g CX-CVM1	125 g CX-CVM1	140 g CX-CVM1	140 g CX-TP1	170 g CX-TP1	170 g CX-TP1	140 g NKG- 814
Wheel-side joint Grease quantity Grease	90 g CX-CVL1	75 g CX-CVL1	80 g CX-CVL1	80 g CX-CVL1	105 g CX-CVL1	105 g CX-CVL1	105 g NKG- 814

NOTE:

CX-CVM1 = Part number: 2 286 016
CX-TP1 = Part number: 2 286 018
CX-CVL1 = Part number: 2 286 017
NKG-814 = Part number: 2 356 850

Push the new bellows onto the output shaft.

Lubricate the joint with lubricant (see table).

NOTE: The sealing surfaces on the inside of the bellows and the groove on the constant velocity joint must be dry, clean and free of grease.

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Position the bellows (3) on the joint.

IMPORTANT: Bellows must be bled after lining in order to adapt the excess pressure generated during lining to the ambient pressure!

Vent bellows; carefully slide a suitable tool between bellows and output shaft for this purpose.

Position the band clamp (1) and (2) in the bellows groove and close it with special tool 32 1 260.

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Installing inner joint bellows:

Slide the band clamp with the smaller diameter onto the output shaft (2).

Slide the new bellows (1) onto the output shaft (2).

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IMPORTANT: Mount the tripod (2) on the output shaft so that the flat side (1) points toward the snap ring.

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Drive tripod (2) with a suitable tool onto the output shaft (3) until the groove for the snap ring is exposed.

Install the snap ring (1).

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Lubricate the joint housing (4) with lubricant (see table).

IMPORTANT: During assembly, the sealing surfaces on the bellows and joint must be clean, dry and free of grease!

Mount the joint housing (4) on the tripod.

Mount the bellows (3) on the joint housing (4).

IMPORTANT: Bellows must be bled after lining in order to adapt the excess pressure generated during lining to the ambient pressure!

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Vent bellows (3); carefully slide a suitable tool between bellows and output shaft for this purpose.

Close the band clamps with the special tool 32 1 260.

If necessary, close the low-profile band clamp with special tool 31 5 200.

Replace transmission snap ring.

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