Withdrawal
Remove the propeller shaft and clean it of dirt.
Tighten the clamps of the corrugated cover of the inner cardan joint with side cutter pliers.
Using a pin, press the sealing cover off the hinge cage.
Squeeze the corrugated cover from the hinge cage and slide it onto the shaft.
Wipe grease off the universal joint with a rag.
Remove retaining ring with suitable pliers.
Using a suitable pin -1-, press propshaft out of inner constant velocity joint -2-. The spherical hub must be in contact with the support plate -3-.
Check universal joint for dirt and damage, replace if necessary. If possible, do not disassemble the cardan joint.
Clean the contaminated hinge, for which it must be disassembled. In this case, the mutual position of the spherical hub, separator and hinge element should be marked from the end surface.
Attention: During assembly, the exceptional cleanliness of the parts must be ensured.
Pull through the profiled inner shaft (differential side) corrugated cover.
If necessary, bite the clamps of the corrugated cover at the outer hinge with wire cutters and remove the cover through the shaft. When removing, make sure that dirt does not get into the hinge.
Installation
To replace the bellows, use the complete repair unit. In cars with increased mileage, it is recommended to replace the second corrugated cover.
Thoroughly clean the assembled CV joint.
Put on new corrugated covers. In order not to damage the corrugated covers when putting them on the cardan shaft, close the places with sharp edges with suitable bushings or paste over with adhesive tape.
Fill the joint with new grease.
Attention: In the repair site "corrugated case" (Faltenbalg) special lubricant available.
Push the inner cardan joint onto the shaft.
Support propshaft on a vise with clamp tool -1-.
Using a suitable tube -2-, push the constant velocity joint onto the shaft as far as it will go.
Remove terminal fixture.
Use suitable pliers to insert a new retaining ring and check that it is correctly positioned in the groove.
Fill the CV joints and corrugated covers at the outer and inner joints with special grease. Make sure that dirt does not get into the hinges.
Amount of lubricant:
- internal hinge 520i, 525tds - 70 g; 523i, 528i, 530i, 540i - 85 g;
- external hinge 520i, 525tds - 80 g; 523i, 528i, 530i, 540i - 100g
Treat the contact surfaces of the sealing cover with Curil T or Stucarit Dicht-Gel 309/4 sealant and press the cover onto the hinge cage.
Treat the contact surfaces of the tips for bellows with Curil T or Stucarit Dicht-Gel 309/4 and press onto the hinge cage.
Fasten corrugated covers on the tips with clamps using tongs, for example, HAZET 1847-1. Make sure that the lock of the large clamp is located between the two holes in the flange of the constant velocity joint.
Put on the bellows for the outer hinge and fasten it to the large diameter.
Pull the corrugated covers through the bulges on the shaft and secure with clamps.
Install driveshaft.