Wheel Drive Shaft Inner Joint and Boot Replacement

Wheel Drive Shaft Inner Joint and Boot Replacement

Special Tools

* J 8059 Snap Ring Pliers (Parallel Jaw)
* J 35910 Drive Axle Seal Clamp Pliers

Removal Procedure





Notice: Do not cut through the wheel drive shaft inboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.

1. Disconnect the swage ring from the shaft using a hand grinder to cut through the ring, taking care not to damage the shaft.
2. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp.
3. Separate the inboard boot from the trilobal tripot bushing (3) at the large diameter.
4. Slide the boot away from the joint along the shaft.




5. Remove the housing (1) from the tripot joint spider and the shaft (2).




6. Spread the spacer ring (1) usingJ 8059 (or equivalent).




7. Remove the spacer ring (1), spider assembly (2), spacer ring (3), if equipped, usingJ 8059, and tripot boot (4). Discard the boot and rings.
8. Clean the shaft (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves).
9. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit.

Installation Procedure





Important: Place a towel in the vise before inserting the shaft.


1. Mount the shaft into a vise.
2. Place the new small eared clamp (2) onto the small end of the joint boot (1). Slide the joint boot (1) and the eared clamp (2) onto the shaft.
3. Position the small end of the joint boot (1) into the joint seal groove (3) on the shaft.




4. Crimp the eared clamp (6) usingJ 35910, a torque wrench (8), and a breaker bar (9).




5. If equipped, install the spacer ring (2) into the groove of the shaft usingJ 8059.




6. Slide the tripot joint spider assembly (4) as far as it will go on the shaft.
7. Install the spacer ring (2) into the groove of the shaftJ 8059.




8. Place approximately half of the grease from the service kit in the shaft inboard boot. Use the remainder of the grease to repack the housing.

Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).


9. Install the trilobal tripot bushing (3) to housing (1).
10. Position the larger new seal retaining clamp (2) on the shaft inboard boot.
11. Slide the housing (1) over the tripot joint spider assembly on the shaft.




12. Slide the large diameter of the shaft inboard boot (2), with larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove.
13. Position the joint assembly at the proper vehicle dimension, a = 106 mm (4.00 in).
14. Carefully insert a thin flat blunt tool, no sharp edges, between the large boot opening and the trilobal tripot bushing in order to equalize the pressure. Remove the tool.




15. Align the following items while latching:

* The shaft inboard boot
* The tripot housing (2)
* The large boot retaining clamp (3)

Crimp the boot retaining clamp withJ 35910 to 176 N.m (130 lb ft). Add the breaker bar (5) and the torque wrench (4) toJ 35910 if necessary.

16. Check the gap dimension (a) on the clamp ear. If the gap dimension is larger than shown, continue tightening until the gap dimension of 2.6 mm (0.102 in) is reached.
17. Fully stroke the joint several times to disperse the grease.