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Front Axle Shaft Replacement
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Posted 11/25/2006 1:27 PM
diehardg
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Date registered: May 2006
Location: Tokyo, Japan
Vehicle(s): 2000G500L, 2015 G350BT, 2016G63(now), 1968 S404
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Front Axle Shaft Replacement

I'd like to share some pictures and thoughts on the job.

Replacement of axle was okay. Hardest part was before getting there. ABS sensor was very hard to come off. They are very long and stuck in the knuckle very hard. You need to pull it hard. ABS sensor is damaged during installation and needs to be replaced.

Somehow, my G is now showing "brake distribution" error. I don't know why. Maybe this is due to damaged ABS sensor. Has anyone seen this error??

Here's the parts that I ordered:

A460 330 40 01 Drive shaft Left Front Axle Joint
A460 330 41 01 Right

A015 997 01 47 Seal Ring Sealing of Drive shaft bearing
A009 981 41 05 Tapered Roller Bearing Inside
A009 981 48 05 Tapered Roller Bearing Outside
A015 997 79 47 Seal Ring Outside
A463 334 01 59 SealRing Wheel Hub
A463 334 00 19 Protective Ring Wheel Hub
A460 331 05 58 Seal Holder inside
A460 331 01 80 Gasket Inside
A460 331 00 80 Gasket Outside
A460 331 03 58 Seal Holder Outside
A460 997 00 40 Seal Ring Kingpin
A000 981 59 05 Tapered Roller Bearing Steering knuckle top and bottom
A460 332 00 33 Expansion Plug Kingpin

Parts that I didn't order but wish I did:
The seal in the axle tube that I circled in red
Lock washer
ABS Sensor



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Attachments
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Attachments P10000700001.jpg (344KB - 7 downloads)
Attachments P10000790003.jpg (284KB - 7 downloads)
Attachments P10000840004.jpg (213KB - 11 downloads)
Attachments P10000900005.jpg (135KB - 8 downloads)
Attachments P10000930006.jpg (275KB - 7 downloads)
#54257
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Posted 11/25/2006 1:45 PM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
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RE: Front Axle Shaft Replacement

Those photos being back many memories of doing this very messy job on my 280GE. Lots and lots of grease. It looks like you definitely did serious damage to the CV joint, too.

My guess is that the error is probably due to the ABS sensor being damaged. It will probably go away once that is fixed.

Thanks for the memories!
#54259 - in reply to #54257
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Posted 11/25/2006 2:32 PM
G wizz
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Date registered: Apr 2006
Location: Uk
Vehicle(s): Dont own a G anymore, Too expensive!!!!
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Re: Front Axle Shaft Replacement

die hard, my friend had the same problem with his G560 when he uses it off road,in fact its only used off road. he has gone through many front CV's due to the cage holding the balls breaking and mashing the shaft. He has since got a company in America to make shafts, and stronger cages for the CV from aircraft landing gear material, (apparently a very strong steel). However he has had to order 10 so he has many spares.If you are interested PM me and I can give you his e Mail here in the UK.
#54270 - in reply to #54257
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Posted 11/25/2006 4:11 PM
hus55
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Date registered: Apr 2006
Location: north cyprus,lapta.
Vehicle(s): 300GDS, G300 LONG,300GDT CLK55 AMG CAB.
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Re: Front Axle Shaft Replacement

i was 17 years old and living in cyprus,i always loved offroading in the mountains with a few mates onboard.well on this occasion i was crawling down a steep bank unaware that the end was a 2 foot drop.BANG!! The momories have all come back.....especially my dads fists!!!
#54272 - in reply to #54257
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Posted 11/26/2006 11:45 AM
-UG-
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Date registered: Jun 2006
Location: Finland
Vehicle(s): GD300, S350 CDI
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RE: Front Axle Shaft Replacement

Here you see why you must always carry a spare CV with you. Once you brake it, you cannot run for much longer before you screw up the shaft too. Just replace it where you brake it.

Here the joint costs 250 eur but the complete shaft with the joint is 800 eur. Don't want to put the extra 550 too many times for nothing.

-UG-
#54345 - in reply to #54257
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Posted 11/26/2006 3:48 PM
roughneck
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Date registered: Apr 2006
Location: UK, Germany & USA
Vehicle(s): 270 cdi.300 GD 300 GE.lwb 300 GE.swb. Disco 2
Posts: 4398
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Re: Front Axle Shaft Replacement

G wizz - 11/25/2006 7:32 PM

die hard, my friend had the same problem with his G560 when he uses it off road,in fact its only used off road. he has gone through many front CV's due to the cage holding the balls breaking and mashing the shaft. He has since got a company in America to make shafts, and stronger cages for the CV from aircraft landing gear material, (apparently a very strong steel). However he has had to order 10 so he has many spares.If you are interested PM me and I can give you his e Mail here in the UK.


Those would be the ones made at my mates, Dave Mac props of Coventry, the contact details have been published previously on this and other forums. He also sorted out the harmonic vibration on Richards 400 cdi,he does marvels with any transmission of power.
#54371 - in reply to #54270
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Posted 11/26/2006 5:13 PM
G wizz
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Date registered: Apr 2006
Location: Uk
Vehicle(s): Dont own a G anymore, Too expensive!!!!
Posts: 686
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Re: Front Axle Shaft Replacement


He also sorted out the harmonic vibration on Richards 400 cdi,he does marvels with any transmission of power.

Using a double cardon joint, which is common practice when lifting the suspension, very common on TD5 Landrovers. The DC's joint he buys are from Bailey Morris.
#54373 - in reply to #54371
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Posted 11/26/2006 6:42 PM
roughneck
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Date registered: Apr 2006
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Vehicle(s): 270 cdi.300 GD 300 GE.lwb 300 GE.swb. Disco 2
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Re: Front Axle Shaft Replacement

G wizz - 11/26/2006 10:13 PM


He also sorted out the harmonic vibration on Richards 400 cdi,he does marvels with any transmission of power.


Using a double cardon joint, which is common practice when lifting the suspension, very common on TD5 Landrovers. The DC's joint he buys are from Bailey Morris.

More information the better, what ever the source.
#54380 - in reply to #54373
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Posted 11/26/2006 7:37 PM
ewalberg
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Date registered: Apr 2006
Location: Past: San Francisco. Present: Germany
Vehicle(s): 2000 g500
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RE: Front Axle Shaft Replacement

Yeah, i broke both of my abs sensors trying to get them out also. It seems some people are able to get them out, but if you're on a timeline, i'd recommend buying two just in case. I drove my car without a sensor for a couple days and i got an ABS error but don't remember what it said. I also noticed that it seemed like ABS system would be slightly engage with hard braking even though it was technically turned off by the car. You could feel slight pulsing in the pedal until i re-fitted the sensor.

If you're still getting errors after re-fitting the new sensor maybe it's nor fully seated? Any chance your replacement CV wasn't for the ABS vehicles? Non ABS CV's are different. Maybe you got a bad connection at the plug side?

Any chance you got your king pin shims mixed up or bearings not fully seated? Maybe if they're off enough, the sensor wont register against the CV joint features that the ABS sensor measures? I was able to detect that i had a king pin issue by feeling the narrowest point of the axle tube. They should both stay nice and cool to the touch. I found the hub at the bearings actually does warm up a little even if you undertension the bearings, but the axle tube shouldn't warm at all. I think it's the axle shaft rubbing against the metal bushing just behind the axle tube seals... the ones you wish you had purchase ahead of time.

How many miles on your truck and did you have any perceptible wheel bearing play before this CV failure? (off topic question, just curious)
#54389 - in reply to #54257
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Posted 11/28/2006 10:44 PM
diehardg
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Date registered: May 2006
Location: Tokyo, Japan
Vehicle(s): 2000G500L, 2015 G350BT, 2016G63(now), 1968 S404
Posts: 220
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Re: Front Axle Shaft Replacement

DUTCH,
Yes, it was lot of grease!! But I was lazy and took it to the shop that I usually go.

hus55,
You've been driving G since 17? Lucky guy!!

G wizz,
Thanks. I will try to get that CV.

UG,
Looks like carrying CV is good idea. If you have to replace CV on trail, it will be a looong day! Hopefully I won't break it again...

ewalberg,
Yeah, I should have bought sensors at the same time. Now my G is in MB shop. Errors need to be reset.
Shaft are same for non-ABS and ABS, i guess. ABS gear is reused from old shaft. They perfectly fit on new shaft.

King pin shim and bearings are okay. After the installation, play is checked and they looked okay.

My G has 60,000km which is 37.5K miles. No wear or play before CV breaks.

Yasu
#54623 - in reply to #54257
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Posted 11/29/2006 8:15 AM
G wizz
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Date registered: Apr 2006
Location: Uk
Vehicle(s): Dont own a G anymore, Too expensive!!!!
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Re: Front Axle Shaft Replacement

Can you remember what you were doing when the cv went, did you have the front diff in, nose down on full lock. Am I correct in saying the cv and shafts have not changed in strength for a 91 463 300 petrol to the present day G500 with twice as much hp and torque ?.

I would try and train yourself by not using the front locker unless in a straight line. The quickest I have seen a cv done on site is 2 hrs. a landrover, 10 minutes.
#54650 - in reply to #54257
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Posted 11/29/2006 9:46 AM
diehardg
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Date registered: May 2006
Location: Tokyo, Japan
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Posts: 220
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Re: Front Axle Shaft Replacement

G wizz - 11/29/2006 9:15 PM

Can you remember what you were doing when the cv went, did you have the front diff in, nose down on full lock. Am I correct in saying the cv and shafts have not changed in strength for a 91 463 300 petrol to the present day G500 with twice as much hp and torque ?.

I would try and train yourself by not using the front locker unless in a straight line. The quickest I have seen a cv done on site is 2 hrs. a landrover, 10 minutes.


I was trying to climb wet rocky hill, steered little bit, steeping on gas about 1/5, moving at walking speed, and hit bump and hopped. When landed, CV failed.

Not sure if CVs are same strength. Part number starts with 460. So, I would guess they are the same...
When climbing, usually front CVs don't get too much weight and stress. So, I thought it's okay but NOT...


2 hours to replace seems very good!

Yasu
#54653 - in reply to #54650
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Posted 11/30/2006 9:32 AM
roughneck
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Date registered: Apr 2006
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Re: Front Axle Shaft Replacement

G wizz - 11/29/2006 1:15 PM
The quickest I have seen a cv done on site is 2 hrs. a landrover, 10 minutes.


But LR people get a lot of practice because they can break them in ten minutes.
#54778 - in reply to #54650
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Posted 11/30/2006 2:19 PM
G wizz
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Date registered: Apr 2006
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Vehicle(s): Dont own a G anymore, Too expensive!!!!
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Re: Front Axle Shaft Replacement

so the wheel was spinning with gas on while in the air, and with gas on when it landed, took hold on the rock and BANG!
#54799 - in reply to #54257
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Posted 11/30/2006 6:48 PM
diehardg
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Date registered: May 2006
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Re: Front Axle Shaft Replacement

G wizz - 12/1/2006 3:19 AM

so the wheel was spinning with gas on while in the air, and with gas on when it landed, took hold on the rock and BANG!


Not in the air. I slightly bounced. Oh, don't forget, steered little bit...

Yasu
#54813 - in reply to #54799
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Posted 12/1/2006 5:17 PM
roughneck
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Date registered: Apr 2006
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RE: Front Axle Shaft Replacement

So back to the axle change, is it completed?
#54924 - in reply to #54257
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Posted 12/1/2006 8:23 PM
diehardg
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Date registered: May 2006
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RE: Front Axle Shaft Replacement

roughneck - 12/2/2006 6:17 AM

So back to the axle change, is it completed?


Yep, MB called me and said ABS sensor was damaged. Should be back on road soon!

Yasu
#54985 - in reply to #54924
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