Cardan shaft joint (Defender 2007+)

Disassembly

1. Remove cardan shaft.

For more information, see the chapter: (205-01 Cardan shaft) Front driveshaft (Removal and installation), Rear driveshaft (Removal and installation).

2. Carefully examine the universal joints for signs of damage or wear.

3. Clean outer races of universal joint bearings and circlips.

CAUTION: To ensure correct assembly and reduce the chance of imbalance, mark the position of the cross in relation to the yoke eyes before removing the propshaft pivot.

4. Remove retaining rings.

5. Mark the position and remove the grease nipple.



6. Tap the forks to remove the bearing outer races.



7. Remove the bearing outer races.

8. Remove the cross.


9. Clean the yokes and bearing outer race locations.

Assembly

1. Remove bearing outer races from new cross.

2. Make sure all needle rollers are present and fit into the bearing outer races.

3. Insert a new cross with seals into the propeller shaft flange yokes.



4. Partially insert one outer race of the bearing into the yoke and insert the cross shaft into the outer race of the bearing.

5. Insert the opposite outer bearing race into the yoke.

6. Press both outer bearing races into place.

7. Press each bearing outer race into the appropriate yoke up to the bottom edge of the circlip groove. If the outer races of the bearings pass beyond this point, damage to the outer races and seals may result.

8. Establish lock rings and check absence of an axial backlash.

9. Install the oiler and lubricate the hinge.

10. Repeat the steps in p.p. 3 to 9 on the opposite end of the cardan shaft.

11. Install the cardan shaft. For more information, see the chapter: (205-01 Cardan shaft) Front driveshaft (Removal and installation), Rear driveshaft (Removal and installation).