Withdrawal
1. Raise the car.
2. Drain the gearbox oil.
3. Remove rear wheels.
4. Remove the brake calipers.
5. Remove the brake discs.
6. Mark the relative position of the driveshaft and pinion yoke.
7. Disconnect the cardan shaft from the yoke. Wrap the bearing caps with electrical tape to prevent loss of the bearing rollers.
8. Hang the cardan shaft to the side on the wire.
9. Measure the turning torque of the gearbox drive gear.
Write down the torque value to check the correct assembly. The cranking torque gives the combined preload in the following assemblies:
- drive gear bearings.
- drive gear seal.
- gearbox housing bearings.
- axle bearings.
- axle seals.
10. Mark the relative position of the universal joint yoke and pinion shaft.
11. Attach the fork locking key to the fork.
12. While holding the fork with a wrench, unscrew the fork fastening nut.
13. Set to key (1) nut (2) and screw (3) fork puller.
14. While holding the yoke with a wrench, turn the puller screw to pull the yoke off the pinion shaft.
Warning: remove the fork seal carefully, do not scratch the seal seat.
15. Using a suitable tool, remove the fork seal.
Warning: remove the fork seal carefully, do not scratch the seal seat.
Installation
1. Using a mandrel, press the oil seal into the axle gearbox housing.
2. Apply sealant to the splines of the universal joint fork.
3. Install the yoke according to the relative position marks made before removal.
4. Use a soft-faced hammer to seat the yoke on the pinion shaft until several threads of the pinion shaft threads come out.
5. Install the washer and screw on the new fork nut.
6. Attach the fork locking key to the fork.
7. Tighten the fork fastening nut so. so that the axial clearance of the gear shaft is almost selected. At the same time, rotate the pinion shaft to ensure the correct seating of the bearings.
8. Measure the torque of the drive gear shaft. Tighten the nut in small increments until the initial torque is exceeded by 0.4-0.6 Nm.
Caution: If the torque of the drive gear is exceeded, the drive gear will have to be removed and the deformable spacer replaced.
9. Once the specified torque is reached, turn the gear shaft a few turns. Check the torque value, adjust the torque value if necessary.
10. Connect the cardan shaft to the yoke.
11. Check and adjust the oil level in the gearbox housing.
12. Install the brake discs.
13. Install the brake calipers.
14. Install the wheels.
15. Fill the gearbox with gear oil.
16. Lower the car.