Outer Joint and Seal Replacement

Wheel Drive Shaft Outer Joint and Seal Replacement

- J 8059 Snap Ring Pliers
- J 35910 Seal Clamp Tool
- J 36652 Drive Axle Clamp Swage Tool

Disassembly Procedure





1. Place protective covers over the vise jaws.
2. Place the halfshaft in the vise.





3. Use a hand grinder to cut through the swage ring (2). Do not damage the outer race (1).





4. Slide the seal down the halfshaft bar (4) and away from the CV joint outer race (1). Wipe all of the grease away from the face of the CV joint.
5. Find the halfshaft bar retaining snap ring (2), which is located in the inner race (3). Spread the snap ring (2) ears apart using J 8059 (or equivalent).
6. Pull the CV joint and the CV joint seal from the halfshaft bar (4). Discard the old CV joint seal.





7. Place a brass drift against the CV joint cage (1).
8. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
9. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts.
10. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2).
11. Repeat this process to remove all six of the balls.





12. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2).
13. Lift out the cage (4) and the inner race.





14. Remove the inner race (1) from the cage (2) by performing the following steps:
14.1. Rotate the inner race (1) 90 degrees to the centerline of the cage (2).
14.2. Rotate the inner race (1) until one of the lands project through a cage window.
14.3. Remove the inner race (1) from the cage (2).
15. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.
^ The inner and outer race assemblies
^ The CV joint cage
^ The chrome alloy balls
16. Dry all the parts.
17. Check the CV joint assembly for unusual wear, cracks, or other damage.
18. Replace any damaged parts.
19. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).

Assembly Procedure





1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary.
2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves.





3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2).
4. Align the lands of the inner race (1) with the windows of the cage (2).
5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward.





6. Insert the cage (4) and inner race into the outer race (1).





7. Place a brass drift against the CV joint cage (1).
8. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts.
10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2).
11. Repeat this process in order to install all six of the balls.





12. Pack the CV joint seal (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
13. Place the new small seal clamp (2) onto the CV joint seal.
14. Slide the CV joint seal (1) onto the halfshaft bar.
15. Position the small end of the CV joint seal into the joint seal groove (3) on the halfshaft bar.






Notice: Refer to Fastener Notice in Service Precautions.

16. Secure the small seal clamp (1) using J35910 (or equivalent), a breaker bar, and a torque wrench.
^ Torque the small clamp (1) to 136 Nm (100 ft. lbs.). Check the gap dimension on the clamp ear.





17. Using your hand, pinch the new swage ring (1) into an oval shape.
18. Slide the distorted swage ring (1) over the large diameter of the CV joint seal.






Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (1) before installation.

19. Slide the CV joint (2) onto the halfshaft bar (1). The retaining snap ring that is inside of the inner race engages in the halfshaft bar groove with a click when the CV joint is in the proper position.





20. Slide the large diameter of the CV joint seal (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (3).





21. Mount J 36652.
22. Pull on the CV joint (1) to verity engagement.

Important: Align the following items during this procedure:
^ The CV joint seal (3)
^ The housing
^ The swage ring (2)

23. Position the CV joint end (outboard end) (1) of the halfshaft bar assembly in the bottom halt of J 36652.





24. Install the top half of J 36652 onto the lower half of J 36652, over the CV joint (1) and the CV joint seal.
25. Align the swage ring and the swage ring clamp.
26. Insert the bolts into J 36652 Hand tighten the bolts until the bolts are snug.
^ Each bolt 180 degrees at a time. Tighten each bolt alternately until both sides of the top half of J 36652 touch the bottom half of J 36652.
27. Loosen the bolts and remove the halfshaft assembly from J 36652.