DRIVE SHAFT INBOARD JOINTS

alternative to: special service tool (18G 1240)

From: "TFP" <colin_xxxxxx@talk21.com>
Newsgroups: alt.autos.mini
Subject: Re: drive shaft question !!
Date: Mon, 29 Jul 2002 23:12:03 +0100

"Tewewest" <stumckinnon@hotxxxx.com> wrote in message
> hi
>
> anyone got tips on getting the inner 
> universal joint off the driveshaft
> other than to use the fancy tool.
>
> it's a 91 mini 998cc
>
> thanks
>
> Stuart
>
>
Put 7/16 nut into 7/16 socket, then put socket 
over nearby bolt (nut means
socket bears on bolt not ally housing cover).  
Then use wide brick bolster,
with edge behind pot joint, using socket as fulcrum.  
A jolt with your hand
on end of bolster usually pops joint out.

TFP.

The offset sphere type joint is used on later manual models and is a splined fit onto the final drive unit stub shaft.
The joint is retained by a circlip on the splined shaft which expands to lock the shaft in the joint.

Joint Replacement

The drive shaft must first be withdrawn out of the inboard joint, as detailed for 'DRIVE SHAFT - Removal' previously.
A special service tool (18G 1240) is required to lever the joint assembly out of the final drive unit, but it should be possible to make up a suitable tool to do the-job. The special tool is shown in

for reference.
Insert the tool between the joint and the final drive unit end cover, with its relieved side against the joint. Drift it into position until the block is adjacent to the end cover bolt

. Give the tool a sharp blow on its outside face to release the joint.
Withdraw the joint assembly from the final drive unit and remove the oil flinger from the joint.
Check the condition of the nylon oil flinger and fit a replacement if it has been damaged in any way.
Insert the new inboard joint into the final drive unit and push it in until the joint is securely engaged over the retaining circlip on the splined shaft.
Refit the drive shaft, following the relevant steps given under the appropriate heading previously.

Boot Replacement

The joint rubber boot should be replaced if perished, worn or otherwise damaged. Before fitting the new boot., the inboard joint should be inspected for any signs of wear, road dirt or corrosion in the joint. If any of these conditions are present, it is recommended that a new joint assembly be fitted.
The joint should be dismantled only if there is reason to believe that it is still serviceable.
To replace the boot, the drive shaft must first be withdrawn out of the inboard joint, as detailed for 'DRIVE SHAFT - Removal' previously.
Remove the outer retaining ring securing the boot to the joint housing. Turn back the boot and remove the inner retaining ring securing the small diameter of the boot to the joint inner member. Remove the rubber boot from the inboard joint.
Inspect the internal components of the joint assembly. If necessary, the joint can be dismantled for cleaning and further inspection as detailed below.
Fit a new 'endless' type retaining clip to the inner neck of the rubber boot, with the chamfered end of the ring towards the inside of the boot (see inset,

). Fold back the boot and fit the smaller diameter over the inner member of the inboard joint. The use of a special mandrel and sleeve (18G 1251) is recommended for this operation to facilitate fitment of the boot

. In this case, the mandrel must be lubricated with a liquid detergent or rubber lubricant to ease fitting.
If necessary, pack the joint with 50 cc of Shell S7274 Tivella 'A' grease. This is normally supplied in a sachet with the new boot kit.
Turn the boot back and locate it on the outside of the joint housing. Secure the boot with a new retaining clip as shown in

. This clip must be fitted with the tab folded back away from the direction of forward rotation of the joint.
Finally, refit the drive shaft following the relevant steps given under the appropriate heading previously.

Joint Overhaul

1. Remove the inboard joint from the final drive unit housing as detailed previously for 'Joint Replacement'.
2. Remove the rubber boot from the joint.
3. Withdraw the joint inner member and ball cage 'assembly from the joint housing.
4. Push the balls out of the ball cage by inserting a screwdriver between the joint inner member and each ball in turn.
5. Rotate the ball cage until the grooves inside the cage coincide with the lands on the joint inner member, then withdraw the cage from the inner member.
6. Clean all the components of the joint and examine carefully for any signs of wear, damage or corrosion pits. Discard the joint if any of these conditions are present.
7. If the joint is in serviceable condition, reassemble the inner member, ball cage and balls in the reverse order of dismantling. Ensure that the long tapered end of the ball cage faces towards the drive shaft end of the inner member.
8. Fit the inner member assembly into the joint housing.
9. Pack the joint with 50 cc of Shell S7274 Tivella 'A' grease. A sachet of grease is normally supplied with a new boot kit.
10. Fit the rubber boot to the joint as detailed above.

refers.
11. Finally, refit the inboard joint to the final drive housing and refit the drive shaft as detailed previously.