Wheel Drive Shaft Inner Joint and Boot Replacement

DISASSEMBLY PROCEDURE

^ Tools Required
- J 8059 Snap Ring Pliers





1. Disconnect the seal retaining clamp from the axle shaft using a with a side cutter. Discard the seal retaining clamp.

IMPORTANT: Do not cut through the drive axle inboard seal and damage sealing surface of the outer housing and the trilobal tripot bushing.

2. Remove the larger seal retaining clamp from the tripot joint with side cutter and dispose.
3. Separate the drive axle inboard seal from the trilobal tripot bushing at the large diameter.
4. Slide the seal away from the joint along the axle shaft.
5. Remove the housing from the tripot joint spider and the axle shaft (1).
6. Spread spacer ring (2) using J 8059.





7. Slide the spacer ring (3) and tripot joint spider (2) back on axle shaft (4).
8. Remove the axle shaft retaining ring (1) from the groove on the axle shaft (4).





9. Slide tripot joint spider (1) assembly off of the axle shaft (3).
10. Clean the following items with cleaning solvent:
^ The tripot balls
^ The needle rollers
^ The housing

11. Remove all traces of old grease and any contaminates.
12. Dry all the parts.
13. Remove the trilobal tripot bushing from the housing.





14. Remove the spacer ring (2) and the seal (3) from the axle shaft (4).
15. Inspect the following parts for damage or wear:
^ The drive axle inboard seal (3)
^ The tripot joint spider assembly (1)
^ The housing
^ The trilobal tripot bushing
^ The tripot balls
^ The needle rollers

ASSEMBLY PROCEDURE

^ Tools Required
- J 35910 Seal Clamp Tool
- J 35566 Earless Seal Clamp Tool





1. Install the small seal retaining clamp on the neck of the drive axle inboard seal. Do not swage.
2. Slide the drive axle inboard seal onto the axle shaft.
3. Position the neck of the drive axle inboard seal in the seal groove on the axle shaft.
4. Crimp the seal retaining clamp (1) using J 35910 to 136 Nm (100 lb ft).





5. Install the spacer ring (2) on the axle shaft (1) and beyond the second groove.





6. Slide the tripot joint spider assembly toward the spacer ring as far as it will go on the axle shaft.
Install the axle shaft retaining ring in the groove of the axle shaft using J 8059.

IMPORTANT: Ensure that the counterbored face of the tripot joint spider faces end of the axle shaft.

7. Slide the tripot joint spider assembly towards the end of the axle shaft.
8. Reseat the spacer ring in the groove on the axle shaft.
9. Place approximately half of the grease from the service kit in the drive axle inboard seal. Use the remainder of the grease to repack the housing. Ensure the bushing is flush with the face of the housing.
10. Install the trilobal tripot bushing to housing. Ensure the trilobal tripot bushing is flush with the face of the housing.
11. Position the larger new clamp on the drive axle inboard seal.
12. Slide the housing (1) over the tripot joint spider assembly on the axle shaft.





13. Slide the large diameter of the drive axle inboard seal (2), with the larger clamp in place (3), over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.





14. Position the joint assembly at the proper vehicle dimension.

IMPORTANT: Align the following items while latching:
^ The drive axle inboard seal (3)
^ The housing (1)
^ The large clamp (2)
Latch the seal retaining clamp (2) with J 35566.

IMPORTANT: The drive axle inboard seal (2) must not be dimpled, stretched out or out of shape in any way. If the drive axle inboard seal (2) is not shaped correctly, carefully insert a thin flat blunt tool (no sharp edges) between the large seal opening and the trilobal tripot bushing to equalize the pressure. Shape the drive axle inboard seal properly by hand. Remove the tool.