156 2.4 JTD outer cv joint replacement - Alfa Romeo Forum
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156 2.4 JTD outer cv joint replacement

I have done dozens of CV joints on many cars in my time, but the 156 is giving me problems and I feel like a rank amateur! Ordinarily, popping a cv joint of the end of the drive shaft requires a couple of taps with a mallet and the circlip releases and the cv joint is then tapped off the driveshaft. I have had a hell of a job trying to remove the circlip from the back of the CV joint. In doing so, temper rising, I inadvertently pulled the whole drive shaft from the gearbox and spilled oil everywhere. I then damaged the CV joint necessitating my smashing off the outer casing so that I could extract the drive shaft. I realised I could have separated the tuning fork to make life easier...

With the drive shaft mounted on the bench, the inner circlip still proved difficult to separate sufficiently to release the CV joint inner cage. While off the car, I fitted a new inner CV joint boot and metal cover fitting new Nylocs. I replaced the driveshaft/gearbox oil seal as a precaution and then refitted the drive shaft. My aim was to fit the CV in situ - big mistake! Ordinarily, I should expect to just tap the CV onto the end of the drive shaft whereby a conventional snap-ring circlip would prevent no problems - But not on this car! So, can anyone tell me how is the circlip fitted? Do I fit the circlip to the drive shaft, line up the CV and tap it through - As with a normal snap ring? I just cannot get the CV splines to pass over the circlip, but I cannot otherwise see how the circlip could be fitted after the CV is fully home. As far as I can see, the circlip can only go on the drive shaft before the CV joint is then fitted, as with other cars. However, the joint will not pass over the circlip. I have checked the forums. Lots of advice but very little on refitting the circlip. Anyone?
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Alfa 156 JTD

Whenever I've had the CV joint off then replaced it, because the end of the drive shaft has a bevel which acts as a cone, as long as the joint is offered up to the shaft squarely the bevel will force open the circlip enough to pass over the full diameter of the splines. Then as the joint is tapped on the circlip will click into the grove on the shaft to hold it in place.
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156 , joint , jtd , outer , replacement

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