Wheel Drive Shaft Outer Joint and Boot Replacement

Disassembly Procedure

^ Tools Required
- J 8059 Snap Ring Pliers

1. Remove the large boot retaining clamp from the CV joint with a side cutter. Discard the boot retaining clamp.
2. Remove the small boot retaining clamp from the halfshaft bar with a side cutter. Discard the boot retaining clamp.





3. Separate halfshaft outboard boot (5) from CV joint outer race (1) at the large diameter and slide the boot (5) away from the CV joint along the halfshaft bar (4).
4. Wipe the grease from the face of the CV joint inner race.
5. Spread the ears on the race retaining ring (3) using J 8059 and remove the CV joint assembly (1) from the halfshaft bar (4).
6. Remove the halfshaft outboard boot (5) from the halfshaft bar (4).





7. Use a brass drift and a hammer,to gently tap on the CV joint cage (1) until it is tilted enough to remove the first chrome alloy ball (2).
8. Tilt cage in the opposite direction to remove the opposing ball (2).
9. Repeat this process until all six balls are removed.





10. Position the CV joint cage (4) and the CV joint inner race 90 degrees to the centerline of the CV joint outer race (1) and align the CV joint cage windows (3) with the lands of the CV joint outer race (3).
11. Remove the CV joint cage (4) and the CV joint inner race from the CV joint outer race (1).





12. Rotate the CV joint inner race 90 degrees to the centerline of the CV joint cage with the lands of the CV joint inner race (1) aligned with the windows of the CV joint cage (2).
13. Pivot the inner race into the cage window (2) and remove the inner race (1).
14. Clean the following items thoroughly with cleaning solvent:
^ The inner and outer race assemblies
^ The CV joint cage
^ The balls
15. Remove all traces of old grease and any contaminates.
16. Dry all the parts.

Assembly Procedure

^ Tools Required
- J 35910 Earred Clamp Tool
- J 41048 Small Swage Tool





1. Place the new small boot clamp (2) onto the small end of the joint boot (1). Slide the joint boot (1) and the small boot clamp (2) onto the halfshaft bar.
2. Position the small end of the joint boot (1) into the joint boot groove (3) on the halfshaft bar.





3. Mount J 41048 in a vise and proceed as follows:
3.1. Position the outboard end (1) of the halfshaft assembly in tool J 41048.
3.2. Align the top of boot neck on the bottom die using the indicator.
3.3. Place the top half of the J 41048 on the lower half of the J41048.
3.4. Before proceeding, ensure there are no pinch points on the halfshaft inboard boot. This could cause damage to the halfshaft inboard boot.
3.5. Insert the bolts (2).
3.6. Tighten the bolts by hand until snug.





4. Align the following items:
^ The halfshaft inboard boot (1)
^ The housing
^ The swage ring (2)
^ Tighten each bolt of J 41048 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.





5. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race (1 ).
6. Hold inner race 90 degrees to the centerline of the cage (4) with the lands of the inner race aligned with the windows of the cage and insert the inner race into the cage.
7. Hold the cage and the inner race 90 degrees to the centerline of the outer race (1) and align the cage windows (3) with the lands of the outer race (2).

Important: Ensure that the retaining ring side of the inner race faces the halfshaft bar.

8. Place the cage (4) and the inner race (2) into the outer race (1).
9. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball.
10. Repeat this process until all six balls are in place.
11. Place approximately half the grease from the service kit inside the halfshaft outboard boot and pack the CV joint with the remaining grease.





12. Push the CV joint (2) onto the halfshaft bar (1) until the retaining ring is seated in the groove on the halfshaft bar.

Important: The halfshaft outboard boot (1) must not be dimpled, stretched or out of shape in any way. If the halfshaft outboard boot (1) is not shaped correctly, equalize the pressure in the halfshaft outboard boot (1) and shape the boot (1) properly by hand.





13. Slide large diameter of the halfshaft outboard boot (1) with the large boot retaining clamp (2) in place over the outside of the CV joint outer race (3) and locate the boot lip in the groove on the CV joint outer race (3).





14. Crimp the boot retaining clamp (1) using J 35910, a breaker bar (3), and a torque wrench (2) to 176 Nm (130 ft. lbs.).