SAFARI

FRONT AXLE - 4

ASSEMBLY

PLUNGING DOUBLE OFFSET CV

JOINT

Clean CV joint components using an approved

solvent.

Apply tape to protect boot during installation.

Slide new small clamp and boot on the side of shaft

having two Circlip grooves. Do not tighten clamp at-

this time.

Assemble inner race, cage and ball assembly.

Install Inner race assembly and two types of new circlip

on shaft.

Pack approximately with 2/3th of specified amount of

grease in outer race.

Place the remaining of grease inside the boot.

Install outer race assembly over ball and cage

assembly.

Push back the inner race with balls & Install large

retaining ring.

Position boot and clamp over CV joint using appropriate

clamp crimper Pt. no. 2704 5890 3332.

Align boot marks on shafts and tighten small clamps.

INSTALLATION OF CV JOINT SHAFT ON

VEHICLE.

Refer the section of removal from vehicle for guide

lines.

Holding the axle shaft assembly with both hands at

the CV joints, insert the axle shaft assembly into

the differential side gear.

Note :

Ensure that the oil seal is not cut or nicked

in above process.

Push the shaft in to place until a click is heard or a

bump is telt as the snap ring engages the end of the

side gear.

Holding the shaft assembly with one hand at the

outboard CV joint, attach the supporting wire.

Assemble the steering knuckles to the ball joint studs.

Assemble the nuts top and bottom and torque to

specification.

CV JOINT FAILURE ANALYSIS

The most common cause of CV failure is due to the

boot failure. While inspecting boots, it is important to

observe the boot for any missing portion, cracks, and

holes, these defects will allow water, dirt, and

contamination to enter joint, as well as the loss of

lubrication. If this occurs, the shaft must be

disassembled and inspected for further damage to

the internal components.

TROUBLE SHOOTING - AXLE

Most drive axle problem fall into the categories of noise

vibration, leaks and failure to transmit power. Problem

diagnosis begins with the customer's complaint, which

includes exact description of the type of noise or

vibration and when it occurs.

This is to be followed by a road test over various types

of road surfaces through the speeds where the

complaint occurs. This helps to locate the fault area

and thus to eliminate it.