Disassembly and Assembly

Fig. 3 Removing boot band:

Fig. 4 Removing circular clip from outer case:

Fig. 5 Removing balls from joint:

Fig. 6 Removing shaft snap ring:

DISASSEMBLY

Double Offset Joint

1. Secure axle assembly in a suitable soft-jawed vise.
2. Remove boot band from differential side joint, Fig. 3.
3. Move boot slightly and remove circular clip, Fig. 4.
4. Separate case from shaft and remove 6 balls with a suitable screwdriver, Fig. 5.
5. Turn ball guide on an angle and move into center shaft side.
6. Remove snap ring from shaft, Fig. 6, then slide out ball guide and retainer.
7. Remove boot from shaft.

Birfield Joint

The Birfield joint must be serviced as an assembly only. However, the boot may be removed in the same manner as described for the Double Offset type joint.
Tripod Joint (TPJ)
1. Apply alignment marks to shaft and case for assembly.
2. Remove large band clip, then joint case.
3. Remove snap ring retaining tripod joint on shaft.
4. Using a brass drift and hammer, drive off tripod joint. Do not hit rollers.
5. Remove small boot retaining band, then boot.

Fig. 7 Inspecting Birfield joint:

Inspection

1. Visually inspect all components and replace those showing signs of damage or excessive wear.
2. Check Birfield joint by bending joint approximately 40° and rotating the shaft to ensure smooth and normal rotation, Fig. 7.

Fig. 8 Installing circular clip in outer case:

Fig. 9 Aligning circular clip ends in outer case:

Fig. 10 Installing boot band:

ASSEMBLY

Double Offset Joint (DOJ)

1. Assemble in the reverse order of disassembly, noting the following:
a. Use care to avoid damaging boot when installing boot on shaft.
b. Install and align circular clip as shown, Figs. 8 and 9.
c. To install boot band, first insert a screwdriver into end of boot, then install band as shown, Fig. 10. Ensure band end clip is securely tightened around the band and boot is not twisted.

Tripod Joint (TPJ)

1. Install small boot band on shaft, then completely cover shaft splines with vinyl tape.
2. Install boot on shaft.
3. Align marks to show joint installation position, insert the shaft into the tripod joint with the shorter spline positioned to the outer side.
4. Install tripod joint on shaft using brass drift and hammer. Do not hit rollers.
5. Install tripod joint snap ring.
6. Apply special grease into tripod housing. Grease is available with repair kit only.
7. Insert a screwdriver into the end of the boot. This will equalize air pressure and give shape to the boot. Install large boot band.