40 FRONT AXLE - 4 X 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 atthis 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, dir t, 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.
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