Outer joint

1 Remove the driveshaft of Fiat Punto.
2 Release the rubber gaiter retaining clips by cutting them off with a pair of side-cutters (see illustration). Remove the clips and slide the gaiter down the driveshaft away from the CV joint.



Release the rubber gaiter retaining dips by cutting them off with side-cutters


3 Using a mallet, sharply strike the edge of the outer joint to drive it off the end of the Fiat Punto driveshaft (see illustrations). The joint is retained on the driveshaft by an internal circlip, and striking the joint in this manner forces the circlip into its groove, so allowing the joint to slide off.



Sharply strike the edge of the outer CV joint to release it from the internal circlip...



... then withdraw the outer joint from the driveshaft


4 Remove the circlip from the groove in the driveshaft splines, and discard it (see illustration). A new circlip must be fitted on reassembly.



Remove the circlip from the groove in the driveshaft splines


5 Slide the old gaiter off the end of the Fiat Punto driveshaft.
6 With the constant velocity joint removed from the driveshaft, thoroughly clean the joint using paraffin, or a suitable solvent, and dry it thoroughly. Carry out a visual inspection of the joint.
7 Move the inner splined driving member from side-to-side, to expose each ball in turn at the top of its track. Examine the balls for cracks, flat spots, or signs of surface pitting.
8 Inspect the ball tracks on the inner and outer members. If the tracks have widened, the balls will no longer be a tight fit. At the same time, check the ball cage windows for wear or cracking between the windows.
9 If any of the constant velocity joint components are found to be worn or damaged, it will be necessary to renew the complete joint assembly as the internal parts are not available separately. If the joint is in satisfactory condition, obtain a new gaiter, circlip, retaining clips, and the correct type of grease. These components are all available individually from Fiat dealers, but may be supplied as a complete repair kit from other sources.
10 Commence reassembly by fitting a new joint retaining circlip to the groove in the end of the shaft.
11 Slide the smaller gaiter securing clip onto the Fiat Punto driveshaft, followed by the gaiter and the large securing clip (see illustrations).



Slide the smaller gaiter securing clip onto the driveshaft...



... followed by the gaiter…



... and the large securing clip


12 Pack the CV joint with the specified grease, then twist the joint to ensure that all the recesses are filled (see illustration).



Pack the joint with the specified grease, then twist the joint to ensure all recesses are filled


13 Fit the CV joint to the Fiat Punto driveshaft, and engage it with the shaft splines. Use a mallet to tap the joint onto the shaft until the circlip engages correctly behind the joint cage (see illustrations).



Engage the CV joint with the driveshaft splines ...



... then tap the joint onto the shaft until the circlip engages


14 Fill the gaiter with any remaining grease then slide the large end of the gaiter into position over the joint, ensuring that it is seated squarely over the joint body.
15 Locate the large securing clip over the gaiter and secure the clip in place by compressing the raised portion (see illustration).



Locate the large securing clip over the gaiter and secure the clip by compressing the raised portion


16 Check that the smaller end of the gaiter is located in the driveshaft groove then, using a small screwdriver, lift the lip of the gaiter to expel any air trapped inside (see illustration).



Lift the lip of the gaiter to expel any air trapped inside


17 Slide the smaller securing clip over the gaiter, and secure it as described previously (see illustration).



Slide the smaller clip over the gaiter and secure it by compressing the raised portion


18 Refit the Fiat Punto driveshaft.

Inner joint

19 Remove the driveshaft.
20 Release the gaiter smaller clip by cutting it off with a pair of side-cutters (see illustration).



Release the smaller clip on the inner joint gaiter by cutting it off with side-cutters


21 Wipe off the excess grease from the tripod and the end of the driveshaft.
22 Using circlip pliers, remove the circlip securing the tripod to the end of the driveshaft (see illustration). Discard the circlip - a new one should be used on refitting.



Using circlip pliers, remove the circlip securing the tripod to the end of the driveshaft


23 Withdraw the tripod and the gaiter from the end of the driveshaft.
24 Thoroughly clean the tripod and rollers, and the end of the driveshaft using paraffin, or a suitable solvent, and dry thoroughly. Carry out a visual inspection of the joint and renew any components as necessary. If the joint is in satisfactory condition, obtain a new gaiter, circlip, retaining clips, and the correct type of grease. These components are all available individually from Fiat dealers, but may be supplied as a complete repair kit from other sources.
25 Commence reassembly by sliding the smaller gaiter securing clip onto the driveshaft, followed by the gaiter.
26 Check that the gaiter is located in the Fiat Punto driveshaft groove, then fit the securing clip over the gaiter and secure the clip in place by compressing the raised portion.
27 Refit the tripod and fit a new circlip to secure the tripod to the driveshaft.
28 Pack the specified grease around the tripod rollers and into the joint body, filling the gaiter with any remaining grease.
29 Refit the driveshaft.