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

Special tools required: 

• 00 5 500
• 11 8310
• 31 5200
• 32 1 260

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 replacement of the left OUTPUT SHAFT  or the right OUTPUT SHAFT .

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

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Removing outer joint bellows: 

Failure to comply with this instruction will result in damage to the constant velocity joint.

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

Detach bellows (3) of joint on wheel side.

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 join grease!

It is imperative to follow the grease and quantities listed in the

Bellows part number	8 618 537 8 618 538	8 618 547 8 618 548	8 618 539 8 618 540	8 618 54 8 618 54
Joint on the transmission end
Grease quantity	125 g	125 g	140 g	140 g
Grease	CX-CVM1	CX-CVM1	CX-CVM1	CX-TP1
Wheel-side joint
Grease quantity	90 g	75 g	80 g	80 g
Grease	CX-CVL1	CX-CVL1	CX-CVL1	CX-CVL1

Push the new bellows onto the output shaft.

Lubricate the joint with lubricant (see table).

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Position the bellows (3) on the joint.

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

Install the snapring (1).

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

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Mount the joint housing (4) on the tripod.

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

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 snapring.

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