Cardan shaft joint (Defender 2007+)

Disassembly

1. Remove the driveshaft.

For more information, please refer to the chapter: (205-01 Cardan shaft) Front propeller shaft (Removal and installation), Rear propeller shaft (Removal and installation).

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

3. Clean the outer races of the universal joint bearings and the retaining rings.

CAUTION: To ensure proper assembly and reduce the possibility of imbalance, mark the position of the crosspiece relative to the yoke eyes before removing the driveshaft joint.

4. Remove the retaining rings.

5. Mark the position and remove the grease nipple.



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



7. Remove the outer bearing rings.



8. Remove the crosspiece.

9. Clean the forks and the bearing outer race areas.

Assembly

1. Remove the outer bearing races from the new crosspiece.

2. Make sure all needle rollers are present and engage in the outer bearing races.

3. Insert the new crosspiece with seals into the forks of the cardan shaft flange.



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

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

6. Press both outer bearing races into place.

7. Press each bearing outer race into its respective fork to the bottom edge of the snap ring groove. If the bearing outer races go past this point, damage to the outer races and seals may occur.

8. Install the retaining rings and check for axial clearance.

9. Install the grease gun and lubricate the joint.

10. Repeat steps 3 to 9 on the opposite end of the driveshaft.

11. Install the propeller shaft. For more information, refer to the chapter: (205-01 Cardan shaft) Front propeller shaft (Removal and installation), Rear propeller shaft (Removal and installation).