Replacing constant velocity ball joints (Fusion)

If you hear knocking in the front drive when driving on turns, check the constant velocity joints. If you feel play when rocking the drive shaft by hand or the protective cover is torn, such a joint must be replaced. There is practically no point in disassembling the outer joint (Birfield). This work is labor-intensive, and if the cover is torn, the dirt that got into the joint has already made the joint parts unusable. It is impossible to replace the joint parts separately, so the best solution is to replace the joint as a whole. In extreme cases, disassembling the inner joint (Tripod) for replacement of grease is allowed, as it is simpler and less susceptible to water and road dirt. The appearance of traces of grease on the joint indicates that the cover is torn.

You will need: a flat-blade screwdriver, side cutters, a punch, and a hammer.

1. Remove the front wheel drive assembly (see "Removal and installation front wheel drives").

2. Clean the parts and inspect the drive:

• the outer constant velocity joint should rotate with light force without jerking or jamming, radial and axial play. If any, replace the joint;

• the inner hinge should move in angular and axial directions with slight force, and there should be no jerking, jamming or radial play. Otherwise, replace the inner hinge;
• the outer and inner hinge protective covers should not have any cracks or tears. Replace damaged covers;
• the wheel drive shaft must not be deformed. Replace a deformed shaft.

3. To replace the outer hinge and its cover use a screwdriver or side cutters to disconnect the clamp lock that secures the large outer hinge cover and remove the clamp.

Note: The clamps for fastening the CV joint protective boots are single-use; replace them with new ones during assembly. As a rule, the clamps are included with the new joint.

4. Slide the protective cover off the hinge housing…



5. ...and knock the joint sleeve off the shaft with a hammer through the punch, overcoming the force of the retaining ring.



6. Remove the outer joint from the shaft splines.

Attention! Disassembling the outer joint is not permitted.

7. Remove the retaining ring by using a screwdriver to pry it out of the shaft groove.

Note: When assembling, replace the retaining ring with a new one. The ring is usually included with the new joint.

8. Remove the small clamp of the outer joint boot in the same way as you removed the large clamp (see item 3).



9. Remove the protective cover.

Note: When installing the hinge, replace the protective cover with a new one. The cover is usually included with the new hinge.

10. Before installing a new outer hinge, fill its cavity with grease (if the hinge was not lubricated by the manufacturer) in an amount of about 100 g. First fill the hinge housing, and then evenly distribute the remaining amount in the corrugations of the cover.

Note: If the lubricant recommended by the manufacturer is not available, you can use domestic molybdenum lubricant SHRUS-4.

11. Install the outer joint boot and the joint in the reverse order of removal. When installing the joint on the shaft, press the joint by hitting the joint shank with a hammer through a soft metal punch until the joint collar is secured with a retaining ring.

Caution: Before securing the hinge cover with a large clamp, pull back the edge of the cover with a screwdriver to equalize the air pressure inside and outside the cover.

Note: The clamps are marked with their diameter. The diameter of the large clamp is 86.5 mm, the small one is 36.5 mm.

12. For disassembling and replacing the inner hinge and its cover remove the clamps securing the hinge cover to its body..





13. …and to the shaft.

14. If you disassemble the hinge to replace the cover and intend to install the old hinge, mark in any way (for example, with a punch, file or paint) the relative position of the hinge housing and the drive shaft.



15. Slide the cover off the hinge housing…



16. …and disconnect the housing from the drive.



17. Mark the position of the joint hub relative to the shaft (see item 14).



18. Using a screwdriver, pry up the retaining ring of the hinge hub…



19. …remove the ring from the shaft groove.



20. Remove the hub with rollers from the shaft splines…



21. …and remove the protective cover from the shaft.



22. Wash all metal parts with kerosene until all old grease is removed.

23. Inspect the rollers, hub and inner cavity of the housing. Scoring, dents and corrosion are not allowed. The rollers should rotate on their bearings freely, without jamming. If faults are found, replace the joint assembly.

24. Install the joint cover on the shaft and secure it with a clamp.

25. Install the joint hub onto the shaft splines, aligning the marks made during disassembly, and secure it with a retaining ring.

26. Fill the cavity of the inner hinge with grease in an amount of about 100 g. First fill the hinge housing, and then evenly distribute the remaining amount in the corrugations of the cover.

Note: If the lubricant recommended by the manufacturer is not available, you can use domestic molybdenum lubricant SHRUS-4.

27. Install the hinge housing, aligning the marks made during disassembly.

28. Place the cover on the hinge body and secure it with a clamp.

Caution: Before securing the hinge cover with a large clamp, pull back the edge of the cover with a screwdriver to equalize the air pressure inside and outside the cover.

Note: The clamps are marked with their diameter. The diameter of the large clamp is 80.5 mm, the small one is 41.7 mm.