Land Rover Fusible CV Conversion Fitting Instructions

KAM LAND ROVER FUSIBLE CV CONVERSION
CV Joint Removal
1. Drive vehicle for 5 miles to preheat axle lubricant.
2. Using a suitable container remove drain plug on axle and swivel housing and allow lubricant to drain. Re-fit drain plugs.
3. Jack and secure vehicle and remove road wheel.
4. Remove brake calliper and secure to chassis ensuring excessive strain is not applied to brake lines.
5. Remove hub-driving member dust cap and external cir-clip and shims from CV shaft.
6. Loosen bolts and remove hub-driving member.
7. Drift locking tab clear of wheel bearing nuts and remove wheel-bearing nuts.
8. With care to avoid damage to hub seal, withdraw hub from stub-axle.
9. Loosen and remove stub axle bolts and mud shield.
10. Remove stub axle from swivel housing. A light knock from a soft-faced mallet may be required to break seal.
11. Withdraw CV joint and axle half-shaft.
KAM Fusible CV Joint Installation
1. Clean remaining lubricant from interior of swivel housing.
2. Clean all mating faces on swivel housing, stub axle, wheel-hub and driving member.
3. Inspect and if necessary replace the lip seal in the swivel-ball. (If replacement is required removal of the swivel-ball from the main axle tube is required.)
4. If necessary remove CV bush from stub-axle and replace with KAM bush (6) as shown in diagram.
5. Replacing the lip seal FRC3099 is also recommended.
6. Slide a maximum of 4 of the supplied shims (3) onto the half-shaft from differential end followed by the shaft to swivel-ball bush (4), slide the remaining shims onto the half-shaft from the CV end followed by the steel spacer (5). The swivel-ball bush must be orientated correctly for the type of swivel ball.
7. Lubricate mating splines between half-shaft and CV joint and using a light tap from soft-faced mallet install the shaft (2) into the CV joint (1).
8. Insert the half-shaft and CV assembly into the axle tube taking care to avoid damage to the seal in swivel ball and locate half-shaft in differential.
9. Dry fit the stub-axle (7) to the CV joint (1). A CV bush adaptor (6) may be required for the CV to suit the stub-axle.
10. Ensuring the stub axle is square to the swivel housing, measure the gap between the mating faces on the stub-axle and swivel housing using suitable callipers.
11. Remove stub-axle and withdraw CV and half-shaft assembly.
12. Remove shims equivalent to the gap measured in step 10. The tolerance on this shimming is from 0.00mm to a clearance of 0.25mm.
13. Lubricate all mating surfaces in the CV joint (1) with swivel grease and insert the CV and half-shaft assembly into the axle.
14. Lubricate the stub-axle bush and lip seal with swivel grease or EP90 gear oil.
15. Insert the stub-axle gasket and fit the stub axle to the swivel housing, the mud shield to the stub axle and tighten the 6off retaining bolts to the specified torque (60Nm or 44lbsft).
16. Fit wheel-hub to stub-axle and tighten hub nuts. Ensure that a new locking washer is fitted and folded over nuts.
17. Fit wire clip (9) to KAM stub shaft (8) in fuse position.
18. Lubricate splined surfaces with EP90 gear oil and insert stub shaft through stub-axle to engage with CV joint.
19. Fit hub-driving member and gasket and tighten 5 off retaining bolts to the specified torque (65Nm or 48lbsft).
20. Press on hub-driving member dust cap.
21. Fit brake calliper to swivel housing and tighten bolts to specified torque (60Nm or 81lbsft).
22. Fill differential housing with specified quantity of recommended gear oil or to fill plug level.
23. Fill swivel housing with recommended lubricant and re-fit fill plug. (Filling is most easily accomplished with the vehicle on steering lock. Care must be taken if working on vehicles on axle stands.)
24. Re-fit road wheels and tighten wheel nuts to specified torque.
25. Test drive vehicle.

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