Driveshafts

Supplement: Revisions and information on later models / Driveshafts

Inboard joint boots (non-Turbo models, September 1987 on) - modification
1 Modified boots have been fitted to the differential ends of the driveshafts on non- Turbo models produced after September 1987.

2 The new boots incorporate a seal/bearing assembly, and it is very important when a boot is being fitted to the driveshaft that it is located as shown in Fig. 13.96.

3 The boot retaining band must be crimped using suitable pinchers at the highest point on the boot.

Intermediate driveshaft
(Turbo ie models)
Description
4 On these models, an intermediate driveshaft is fitted between the final drive of the transmission and the flange of the right-hand driveshaft.

5 A support bearing assembly for the intermediate shaft is bolted to the engine crankcase. The bearing carrier also acts as the alternator bracket.

Removal
6 Drain the transmission oil. Disconnect the right-hand driveshaft from the intermediate shaft flange, move the driveshaft aside, and support it.

7 Unscrew and remove the bolts which hold the intermediate shaft retainer plate to the crankcase support bracket.

8 Withdraw the intermediate shaft from the final drive housing. The shaft assembly, complete with bearing, will pass through the crankcase support bracket until the bearing retainer and flexible boot can be slipped off the shaft.

Bearing renewal
9 The bearing on the intermediate shaft can be renewed after removing the plate, circlip and washer, and pressing the shaft out of the bearing.

10 When fitting the new bearing, apply pressure only to the inner track, and do not apply any heat.

Refitting
11 This is a reversal of removal. Tighten all bolts to the specified torque and replenish the transmission oil.

Inboard CV joints (Turbo ie models) - overhaul
12 A worn joint is best renewed, but it may be necessary to dismantle it for cleaning, if replacement of a split boot has been neglected.

13 Disconnect the boot securing clip and pull the boot up the shaft. Wipe away the old grease.

14 Extract the joint securing circlip and pull the joint from the shaft.

15 Renew the joint complete if it is worn or damaged.

16 Before dismantling the joint, align the housing and ball cage marks “A” and “B” (Fig. 13.100).

17 Tap the joint from its backplate.

18 Turn the ball/cage assembly through 90º, mark its relative position to the outer track and withdraw it (photo).

13.18 Removing inboard CV joint ball/cage assembly from outer track

19 The balls are a light snap fit in the cage.

Once they are removed, the inner and outer cage members can be separated; again, mark the side of the cages in relation to the outer track (photos).

13.19A CV joint balls and cage

13.19B Separating inner and outer cage members

13.19C Components of CV joint

20 When reassembling, pack the joint with special FIAT Tutela MRM2 lubricant; if this is not available, use molybdenum disulphide grease.

21 The reference groove on the outer track must be assembled so that it is towards the final drive when refitted (photo).

13.21 Outer track reference groove

22 Pack the joint and the inside of the boot liberally with the specified grease.

23 If a new joint is being fitted to the shaft, make sure that the joint and shaft colour codes match.

Shaft colour Joint colour Blue Blue or white
Red Red or white
Right-hand driveshaft damper weight (1108 cc and
1372 cc ie models) -
removal and refitting
24 A damper weight is fitted to the longer, right-hand driveshaft to reduce vibration (photo).

13.24 Right-hand driveshaft damper weight

25 It should not be necessary to remove the damper weight unless the driveshaft is to be renewed, or the weight has been damaged.

26 The weight is in two halves, and can be removed by simply unscrewing the two clamp bolts securing the two halves to the driveshaft. Note that the weight locates on a rubber mounting which is split along its length, and can simply be pulled from the driveshaft for renewal if necessary.

27 Refitting is a reversal of removal, but ensure that the damper weight is positioned exactly as shown in Fig. 13.101.

Fig. 13.96 Driveshaft boot positioning diagram - later non-Turbo models (Sec 13)

Left-hand shaft
With 4-speed transmission, A = 143.0 mm (5.63 in)
With 5-speed transmission, A = 133.0 mm (5.24 in)
Right-hand shaft
With 4-speed transmission, A = 123.0 mm (4.84 in)
With 5-speed transmission, A = 108.9 mm (4.25 in)
B = 0 to 1 mm (0 to 0.04 in)

Fig. 13.97 Crimping the driveshaft boot securing band (Sec 13)

Fig. 13.98 Components of the intermediate driveshaft - Turbo ie models (Sec 13)

1 Bearing retaining plate 2 Ball bearing
3 Wave washer
4 Circlip
5 Bearing cap

Fig. 13.99 Extracting the CV joint circlip - Turbo ie models (Sec 13)

Fig. 13.100 CV joint housing and ball cage alignment marks (A and B) - Turbo ie models (Sec 13)

Fig. 13.101 Correct position of driveshaft damper weight on 1108 cc and 1372 cc ie models (Sec 13)

Dimensions in mm