Xantia Activa Leaky Ram Repairs: Page 2
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The first job is to remove the top balljoint. For this you will need a thin 14mm spanner to engage with the flats on the top of ram piston just below the balljoint washer. Pull the concertina gaiter down and slip the spanner in. Then, using the spanner to counter hold the piston, undo the balljoint using a pair of pipe grips or similar, taking care not to damage the balljoint. It will be tight. It is likely a suitable spanner will need to be made by thinning down a cheap spanner on a grinder. Take care not to damage the flats on the piston.
Removing the Top Balljoint -
Remove the concertina gaiter. Note the flexi pipe unions are sealed to prevent dirt ingress.
Removing the Concertina Gaiter -
wrap sellotape around the top of the ram pison to avoid damage to the oil seal in the top of the black sleeve..
Applying Protective Tape to the top of the Piston -
The black sleeve must now be removed. The intentional leakage from the ram piston flows between this sleeve and the ram body and is collected by the collar for return to the LHM reservoir. To prevent leakage spilling above the sleeve, there is an oil seal in the top. The sleeve is a very tight fit and is best pulled off using a puller. Fit a flat bearing puller around the "olive" at the bottom of the sleeve and using a two-legged universal puller working against the piston, pull the sleeve up and off. Take care not to damage the balljoint threads at the top of the piston; use a mandrel if necessary.
Removing the Black Sleeve -
Remove the old leakage return collar. It will simply pull up and off. It may be discarded.
Removing the old leakage Return Collar -
The black sleeve is too long as it stands for use with the new XM gaiter and it must be trimmed down.If not trimmed, the flare at the base of the sleeve will block the outlet pipe on the new gaiter. Carefully cut off the flare using a small hacksaw just below the "oilve". Then carefully cut off the "olive" as you will need it later to form a new securing ring for the base of the concertina gaiter.
Trimming Down the Black Sleeve -
After trimming down the black sleeve it is VITAL that all traces of swarf are removed from the sleeve. use an air line and wash it out with solvent. carefully grind off any sharp edges remaining from the trimming operation. Check again for any remaining swarf.
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To ensure the new gaiter has a good lower sealing surface, it is necessary to remove any corrosion from the area where the lower edge of where the new gaiter will sit, just above the flexi pipe unions. A lathe can be used as shown to cut a new, clean surface.
Preparing a Sealing Surface for the New Gaiter using a Lathe -
The trimmed sleeve may now be refitted. Observe that the ram body has two dimples near the top. When refitting the sleeve ensure the "pips" on the side of the sleeve line up with the dimples in the body. Slide the sleeve on, being careful not to damage its oil seal as it slips over the top of the piston.
Replacing the Black Sleeve -
Drive the sleeve fully home using a large socket as a mandrel and a soft hammer. Take care not to distort the sleeve and ensure the sleeve is right home.
Driving the Sleeve Home