Wheel Drive Shaft Inner Joint and Boot

Disassembly Procedure

^ Tools Required
- J 8039-A Snap Ring Pliers





Important: Do not cut through boot and damage sealing surface of outer housing (1).

1. Remove the small retaining clamp from the halfshaft bar (4) with a side cutter. Discard the small retaining clamp.
2. Remove the larger boot retaining clamp from the inboard joint with a side cutter. Discard the boot retaining clamp.
3. Separate the housing assembly (1) from the boot at large diameter.
4. Slide boot away from joint along halfshaft bar.
5. Before removing the tripot spider assembly (3) from the halfshaft bar, perform the following procedure:

Important: Never reuse the spacer ring (2).





6. Remove the spacer ring (2) from the end of the halfshaft bar using J 8039-A.





7. Place a brass drift on the area of the tripot spider (1) next to the halfshaft bar (3).
8. Tap on the brass drift with the hammer.

Important: Handle the tripot spider assembly (1) with care.

9. Remove the tripot spider assembly (1) from the halfshaft bar (3).





10. Remove the spacer ring (1) from the shoulder of the halfshaft bar using J 8039-A.
11. Clean the following items thoroughly with cleaning solvent. Removing all traces of old grease and any contaminates.
^ The tripot balls
^ The needle rollers
^ The housing
12. Dry all the parts.
13. Remove the boot from the halfshaft bar.
14. Inspect the following parts for damage or wear:
^ The joint boot
^ The spider (3)
^ The housing
^ The tripot balls
^ The needle rollers
^ The retaining ring (1)

Assembly Procedure

^ Tools Required
- J 35910 Seal Clamp Tool

1. Install the new small boot retaining clamp on the neck of the boot.
2. Do not crimp the small boot retaining clamp.
3. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves).
4. Slide the tripot boot onto the halfshaft bar, passing the boot grooves of the halfshaft bar toward the CV end of the halfshaft bar.





Important: Ensure that the spacer ring (1) is next to the shoulder of the halfshaft bar before installing the tripot spider (3).

5. Place the new spacer ring (1) next to the shoulder on the halfshaft bar.
6. Place the tripot spider assembly (3) onto the halfshaft bar.





7. Place the halfshaft assembly onto the arbor press.
^ The tripot spider assembly must be on the press plate.
^ The CV joint assembly must be under the press head.
8. Lower the arbor press head onto the CV joint assembly until the tripot spider is next to the spacer ring. Do not exceed 4,000 lbs. press load during assembly.
9. Remove the halfshaft assembly from the arbor press.





10. Place the new spacer ring (2) on the halfshaft bar groove at the end of the halfshaft bar.





11. Slide the tripot boot (7) the corresponding groove on the halfshaft bar.
12. Crimp the small boot retaining clamp (6) using J 35910.
13. Place approximately a 1/2 of the grease from the service kit in boot. Use the remainder to repack the housing.





14. Slide the housing (1) over the spider assembly on the shaft (2). Engage the tripot boot.

Important: The end of the tripot boot (3) must be next to the boot stop on the housing (1).

15. Position the large boot retaining clamp around the tripot boot (3).
16. Position joint assembly at the proper vehicle dimension.





Important: The boot (2) must not be dimpled, stretched or out of shape in any way. If the boot (2) is not shaped correctly, carefully equalize pressure by disassembling and reassembling the housing (4) into the large boot opening at proper vehicle dimension.

Important: Align the following items while latching:
^ The boot
^ The housing (1)
^ The large boot retaining clamp (2)





17. Crimp the large boot retaining clamp (2) with J 35910.