Drive shaft outer joint - KV6

Refit

1. Clean ends of drive shaft and locations in hub and differential.
2. Lubricate oil seal running surfaces.
3. Fit drive shaft to differential and push fully home.
4. Clean ball joint taper and check to ensure ball joint boot is not damaged.
5. Pull knuckle outwards, engage shaft to hub and locate ball joint to lower arm.
6. Fit ball joint nut and tighten to 90 Nm.
7. Fit suspension yoke over lower arm, engage yoke to damper ensuring pip on damper engages with slot in yoke. Fit bolt securing yoke to damper and tighten to 65 Nm.
8. Fit bolt securing yoke to lower arm but DO NOT tighten.

NOTE: Bolt to be tightened with vehicle weight on suspension.

9. Fit NEW drive shaft nut and tighten to 395 Nm.
10. Stake nut to shaft.
11. Fit speed sensor. See MANUAL GEARBOX - ’T750’, Repairs.
12. Remove container.
13. Clean exhaust and turbocharger outlet elbow mating faces and fit NEW gasket.
14. Connect front pipe flange to turbocharger outlet elbow.
15. Fit turbocharger heat shield bracket, fit flange nuts and tighten to 45 Nm.
16. Fit and tighten bolt securing turbo charger heat shield to bracket.
17. Align manifold heat shield, fit bolts and tighten to 8 Nm.
18. Connect battery earth lead.
19. Fit engine acoustic cover.
20. Fit road wheel(s) and tighten nuts to correct torque. See INFORMATION, Torque wrench settings.
21. Remove stand(s) and lower vehicle.
22. Tighten nut and bolt securing yoke to lower arm to 90 Nm.
23. Check and top-up gearbox oil. See MANUAL GEARBOX - ’T750’, Adjustments.

DRIVE SHAFT OUTER JOINT - KV6

Service repair no - 47.10.04

Remove

1. Remove drive shaft. See this section.
2. Place drive shaft in vice.

3. Release both gaiter clips and discard.
4. Slide gaiter along shaft to gain access to outer joint.
5. Using a suitable drift against the inner part of joint, remove joint from shaft.
6. Inspect gaiter for damage and renew if necessary.
7. Remove circlip from shaft and discard.

Refit

1. Clean drive shaft and gaiter.
2. Fit new circlip to shaft.
3. Position outer joint to shaft, use a screwdriver to press circlip into its groove and push joint fully onto shaft.
4. Apply grease from the sachet to the joint.
5. Position gaiter to joint and use a Band-it Thriftool to secure the 2 new clips.
6. Fit drive shaft. See this section.