Doing CV's DIY

Discussion in ''How To' & 'Handy Hints'' started by StevieVW, Jan 9, 2009.

  1. StevieVW

    StevieVW Well-Known Member

    Messages:
    3,470
    Location:
    Somerset, Tasmania
    Two of my four Microbus's CV boots were busted so I'm replacing all four.

    This may could also help you if you have a bum CV, just pack and replace instead of clean and inspect!

    Be ready to have grease on your here's, there's and every where's

    And so, onward and upward! Remember please, safety at all times.

    I used:

    4 CV boot kits; Thanks Roy,
    6mm allen key,
    Lots and lots of clean rags,
    A big socket or similar to help ease the CV's back on the shaft,
    A hammer,
    A punch,
    A fair bit of parts cleaner,
    Cir clip pliers,
    A vice,
    Flat blade screwdriver for making sure the cir clip is seated where it should.




    [​IMG]

    First of all I pulled the old CV out. You may need a special tool to undo your 24 bolts/screws I was lucky and the previous person used allen key head bolts/screws so it was pretty easy for removing them, if your not as lucky you may need a special 12 point tool to undo your bolts/screw.



    [​IMG]

    Here's the trans axle end I cleaned all the old cruddy grease out, ready for reinstalling the axle shaft.



    [​IMG]

    This is the other end as you may have guessed by the presence of the wheel, same again clean the old grease off as above.



    [​IMG]

    Right then, down to business, off we go to the parts washer and wipe the grease off the cir-clip ready for dis assembly.
     
    Last edited: Jan 9, 2009
  2. StevieVW

    StevieVW Well-Known Member

    Messages:
    3,470
    Location:
    Somerset, Tasmania
    [​IMG]

    OK remove the cir clip with cir clip pliers if you have them, it is possible with two screwdrivers but the right tools make it so easy, I'd recommend springing for a set of these pliers, so much quicker easier and less frustrating!


    [​IMG]

    I was lucky here the CV came off the shaft with very minimal effort. If it's hard to get off the John Muir books says you can put it in a vice or similar and knock the axle shaft out with a drift punch, just watch them toes as the shaft falls through the vice!


    [​IMG]

    OK CV and axle shaft apart!


    DON'T MIX CV PARTS, John Muir says so.

    [​IMG]

    OK now rock the CV inner race to the side and remove the balls one at a time... They can be a little stuck so a small screw driver to pop them out of the cage can be handy.
     
    Last edited: Jan 9, 2009
  3. StevieVW

    StevieVW Well-Known Member

    Messages:
    3,470
    Location:
    Somerset, Tasmania
    [​IMG]

    Until you can take the inner race and cage out of the outer race, some balls may remain.


    [​IMG]

    OK now take apart the inner bearing race and the cage.
     
  4. StevieVW

    StevieVW Well-Known Member

    Messages:
    3,470
    Location:
    Somerset, Tasmania
    Now the clean everything thoroughly so you can inspect for wear and/or damaged parts. Clean the bolts, little flat plates and any other parts, I kept any left over bits at the end as spares.



    [​IMG]

    [​IMG]

    [​IMG]

    OK now to check to see if any or your CV's need replacing;

    -If your balls are pitted or have gouges this is bad as are black or blue balls(Not just in the case of CV's), shiny balls are good.
    -Shiny spots (On inner and outer races) where the balls work back and fourth are OK but you don't want grooves.

    My CV's were all looking pretty good, with only one of mine indicated any wear as far as I was concerned; but not enough to warrant replacing.
     
  5. StevieVW

    StevieVW Well-Known Member

    Messages:
    3,470
    Location:
    Somerset, Tasmania
    [​IMG]

    [​IMG]

    OK lets put this show back together, inner race in the cage.


    [​IMG]

    Outer and inner race ready to go back together.


    [​IMG]

    Sit inner race and cage in outer race.
    IMPORTANT: The Grooves where the balls run do NOT line up they must be off set or the joint wont pivot. Will only work one way around.
     
  6. StevieVW

    StevieVW Well-Known Member

    Messages:
    3,470
    Location:
    Somerset, Tasmania
    [​IMG]

    OK now rock the inner race to fit the balls in, you may have to pick it up off the bench to get the last few in.


    [​IMG]

    IMPORTANT: The Grooves where the balls run do NOT line up they must be off set or the joint wont pivot. Will only work one way around.


    [​IMG]

    OK CV assembled.


    [​IMG]

    OK clean up your axle shaft and remove the old boots and get a friend or a vice to the shaft ready for your CV.
     
  7. StevieVW

    StevieVW Well-Known Member

    Messages:
    3,470
    Location:
    Somerset, Tasmania
    [​IMG]

    First put the shaft to boot clamp on(Don't clamp it until your CV is on and the cir clip in place), then the CV boot, then the cup washer as in picture.


    Now pack your CV with grease, I got over 3/4 of the grease that came with my new boots in the CV's then the rest in the CV boots.


    [​IMG]
    OK now slide your CV onto the shaft(The groove on the outer race goes to the boot/shaft end), if it is reluctant to go on; a little persuasion may be necessary. Once you have the CV far enough down the shaft, put the cir clip on and make sure it sits nicely in its groove. Then line up the CV boot so the holes in the boot and outer race line up.


    [​IMG]

    Do the other end and you'll end up with something like this....


    [​IMG]

    A friend to help hold the CV up while you bolt it in is handy but I managed by myself. Watch out for your balls dropping out if you get too much angle on your CV. I bolted to the wheel end first (remember the plates, 3 per CV), then with the trans axle in neutral lined up the trans axle end holes and bolted them on and tightened them up to 25ft*Lbs. You'll have to spin the wheels around so you can roll your bus or jack it up(And block it) and spin the wheel. Check everything is done up, Your Done!

    Apart from being a very messy job, it was a lot easier than I thought it would be.




    If I missed anything, or haven't done something right, please let me know and I'll get it sorted.
     
  8. ttmck

    ttmck Super Moderator Staff Member

    Messages:
    2,783
    Location:
    Hallett Cove STH AUS
    sticky my good friend now go and wash your hands !!
     
  9. nikferatu

    nikferatu Active Member

    Messages:
    1,450
    Location:
    Bracken Ridge, Brisbane
    I was going to do a post when I did this job but you got around to it first! A top effort and nothing left out that I can see. Well done!

    An allen head socket with ratchet and a few different extensions makes this dirty job a little more user friendly in the long term but that's a matter of personal taste...

    Bloody good work!
     
  10. petegardem

    petegardem Member

    Messages:
    102
    Location:
    maclean NSW
    Good job bros ,
    thats why I love this site . Ive always paid mechanics to do that sort of stuff , but with a bit of advice we can all save a fortune and have self satisfaction .
    well done .
    Pete:)
     
  11. Rev.

    Rev. Active Member

    Messages:
    1,435
    Location:
    Eastwood NSW
    Excellent - I have been planning to do this, now I am inspired.

    Rev.
     
  12. gsa2at

    gsa2at New Member

    Messages:
    1,699
    Location:
    MAROOCHYDORE
    i also used a socket with and extension and a 8mm allen key bit

    i also taped the spline when putting the boot oin so as not to damage it

    BTW WD40 gets grease off hands:D
     
    Last edited: Feb 3, 2009
  13. Craig54

    Craig54 New Member

    Messages:
    46
    Location:
    Gold Coast
    Wow thanks a lot
    Thats fantastic

    Craig54
     
  14. Doc

    Doc Active Member

    Messages:
    2,928
    Location:
    Gunnedah
    I used a rattle gun and an allen key socket I was unable to loosen them by hand
     
  15. StevieVW

    StevieVW Well-Known Member

    Messages:
    3,470
    Location:
    Somerset, Tasmania
    I broke my first allen key off by the way, they were tight...
     
  16. Doc

    Doc Active Member

    Messages:
    2,928
    Location:
    Gunnedah
    Not to take anything away from Stevies most excellent article I have had to replace three of the four CV's in Myfanwy (Circa 1974)

    This article from Ratwell was helpful as they are the same as the new cv's that The Busstop supplies.

    http://www.ratwell.com/technical/FAQ/FAQContent.html

    I was unsure as to which side went where and Bentley was unhlepful as was Muir. Also Ratwell takes up the issue of the cup washer to use or not to use I'll leave it to the readers discretion.


    Specifically this is the most helpful picture
    [​IMG]
     
  17. OberonViking

    OberonViking Active Member

    Messages:
    1,809
    Location:
    Bathurst, NSW
    Great thread!
     
  18. Doc

    Doc Active Member

    Messages:
    2,928
    Location:
    Gunnedah
    Don't tell Kombiwidow where I was working
    [​IMG]
    [​IMG]
     
  19. Doc

    Doc Active Member

    Messages:
    2,928
    Location:
    Gunnedah
    I reassembled the Rear axles today. There is a debate about using the dish or cup washer that originally the CV joint sits on. Bentley says it was discontinued after 1975, Ratwell says he wouldn't use it ......but Myfanwy is 1974 so I tried to use it. I ended up having to pull the freshly repacked CV's back of the shafts and remove the dish washer as the circlip washer does not snug home if you use it. Why? I have a feeling that the original CV's were probably pressed onto the axle and a machine put the circlip home it certainly wont snug in its groove without force. Perhaps if you used the old dishwasher it may fit as it wont be as dished but hey it says not use it. Here are some pictures of my exploits.

    Everything Laid out ready to go, note if you buy the cv kits it doesn't come with washers or brakets so you must get those from your old cv's
    [​IMG]
    The new bolts are triple square (or double hex)
     
  20. Doc

    Doc Active Member

    Messages:
    2,928
    Location:
    Gunnedah
    I had already cleaned and painted the axle and so all I had to do was get the clips and then the boots on.[​IMG]

    I also noted that one of the circlips in the kit was of more modern design ?called an e clip anyway a thousand times easier to put on
    [​IMG]

    The dish washer was not used in the end as you cant get the circlip on the end of the axle
     

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