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Sunday, March 9, 2014

How to Install a CV Shaft

The idea of the front-wheel-drive trans-axle was introduced in the early Twentieth Century. Many of the initial designs were not practical and failed due to complex manufacturing processes and reliability issues. In 1929, the Birmingham Small Arms Company introduced a front-wheel-drive trans-axle design in which the engine of the vehicle was mounted transverse, or sideways, in the compartment. This design resulted in the first successful production of a consumer based, front-wheel drive vehicle. Today, most automobiles manufactured are produced with a front-wheel drive trans-axle. Installing a CV shaft can be performed with common tools and moderate automotive repair knowledge.

Instructions

Disconnect the negative cable from the vehicles battery.

Raise the front of the vehicle off of the ground using a jack.

Place jack stands under the front frame support on each side, and lower the vehicle onto the jack stands. Make sure the vehicle is safely supported and remove the jack.

Locate the CV shaft input on the right side of the transmission.

Push the end of the CV shaft into the transmission by hand until the inner CV shaft clicks into place inside the transmission. Make sure not to damage the side seals on the transmission during this process.

Install the inner bearing retaining bolts using a torque wrench and socket and tighten the bolts to the manufacturers recommended torque level.

Pull out the right side strut assembly by hand and insert the outer CV shaft into the hub assembly. Release the right side strut assembly.

Insert the ball joint stud into the steering knuckle. Install the ball joint retaining bolt and nut, and tighten using a torque wrench and socket to the manufacturers recommended torque level.

Install the axle nut washer and axle nut. Tighten the axle nut using a torque wrench and socket to the manufacturers recommended torque level.

Insert a new cotter pin through the axle. Bend the ends of the cotter pin around the axle using needle-nose pliers

Install the wheel assembly and wheel lug nuts. Tighten the lug nuts using a torque wrench and socket to the manufacturers recommended torque level.

Raise the front of the vehicle off of the jack stands using the jack. Remove the jack stands, lower the vehicle to the ground and remove the jack.

Connect the negative cable to the vehicles battery.

Monday, December 9, 2013

How to Remove Inner CV Joints From a 1993 Toyota Corolla

It often starts with a loud popping sound while youre turning. A worn or damaged constant velocity, or CV, joint. The CV joints provide the flexibility that allows the wheels to turn. The inner CV joint is a plunging tripod joint connected to the transmission. The plunging action allows the axle to extend and contract as the suspension moves up and down. Power from the transmission transfers to the driving wheels through the axle shafts. An outer CV joint is splined to a hub on the axle. A rubber boot shields each CV joint and contains the lubricant.

Instructions

Put the wheels straight ahead and set the emergency brake.

Raise the vehicle with vehicle ramps or a sturdy jack on solid ground. Support the vehicle with jack stands, ramps or both for safety. If the vehicle falls, it can seriously damage the vehicles components. It can also seriously injure or kill anyone around or under it.

Remove the front wheels and disconnect the anti-lock brake system speed sensor.

Disconnect the cotter pin and remove the axle shaft lock nut cap. Have a second person apply the vehicles brakes and remove the axle shaft/bearing lock nut. Detach the engine undercover.

Drain the transmission fluid into a container while avoiding spills. Recycle the fluid by taking it to a local auto parts store. Federal law prohibits disposal in sewers, drains or on grass.

Disengage the tie rod from the steering knuckle. Disconnect the steering knuckle from the lower control arm.

Separate the axle shaft from the bearing hub using a hammer or puller. Use a pry bar to separate the left axle shaft from the transaxle.

Use your hammer and a tapping fork to separate the right axle shaft from the transaxle. Be careful. Avoid damaging the speed sensor serration on the drive shaft. Toyota recommends removing the right axle shaft and the intermediate shaft as a complete assembly.

Manipulate the inner CV joint. Make sure it slides smoothly in the thrust direction. Ensure radial movement is free from excessive play. The expected range is between .08 and .12 inch of play in the shaft and too tight to pull out by hand.

Remove the CV joint boot clamps and slide the boots away from the joint. Examine the boots. If there are signs of cracks or leakage, you must replace them.

Mark each component of the CV joint housings, tripod joints and shafts as re-alignment references before disassembling them. After completing the reference marks, disassemble the axle shafts.

Sunday, October 27, 2013

How to Remove a CV Carburetor

The CV, for constant velocity, carburetor was standard equipment on Harley-Davidson motorcycles until 2007, when Harley began delivering all bikes with electronic fuel injection. It has also been standard on Kawasakis and BMWs. It is often called a Keihin carb because it was originally manufactured by that Japanese carburetor maker, although it is a British invention. The CV has a vacuum-operated slide that changes the size of the venturi, the big air hole, in the carburetor to make a constant air velocity. In general, it comes off all bikes as it comes off a carbureted Harley.

Instructions

Start the motorcycle with the petcock closed and run the motorcycle until the carburetor runs out of fuel. Unclip the choke knob from its attachment just in front of the riders left thigh under the fuel tank.

Loosen one or more air cleaner cover bolts on the middle-right side of the motorcycle with a Torx or Allen socket, depending on your motorcycle, and a socket wrench. Disconnect the breather tubes that plug into the top of the air cleaner by hand.

Unbolt and remove the air cleaner with a Torx or Allen socket, depending on your motorcycle, and a socket wrench. Remove the air cleaner.

Loosen the hose clamp that attaches the fuel line to the carburetor with a flat-head screwdriver. Pull the fuel line from the carburetor by hand.

Mark the throttle and idle cables for later assembly with masking tape and a pen and unscrew the cables from the throttle cam.

Unbolt and remove the air cleaner backing plate with a Torx or Allen socket, depending on your motorcycle, and a socket wrench. Remove the air cleaner backing plate by hand.

Grab the CV carburetor with both hands and gently pull it from the rubber boot that attaches the carburetor to the intake manifold. Remove the carburetor and the choke assembly from the right side of the motorcycle as a unit.