Wheel Drive Shaft Inner Joint and Seal Replacement (Delphi)

Wheel Drive Shaft Inner Joint and Seal Replacement (Delphi)

^ Tools Required
- J 8059 Snap Ring Pliers
- J 35910 Drive Axle Seal Clamp Pliers
- DT 47732 Drive Axle Swage Ring Clamp

Disassembly Procedure





Important: With removal of the wheel driveshaft for any reason, the transmission sealing surface (the tripot male/female shank of the wheel driveshaft) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent in a rotation motion. Do not clean with an oscillating motion. Transmission fluid may be used to clean off any remaining debris. The surface should be wiped dry and the wheel driveshaft reinstalled free of any buildup.

1. Use a hand grinder in order to cut through the swage ring. Do not damage the tripot housing (1).
2. Remove the large boot retaining clamp from the tripot joint with side cutter.
3. Dispose of the large boot retaining clamp.

Notice: Do not cut through the wheel drive shaft inboard seal during service. Cutting through the seal 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.

4. Separate the wheel driveshaft inboard boot from the trilobal tripot bushing (3) at the large diameter.
5. Slide the boot (4) away from the joint along the shaft.
6. Remove the housing (1) from the tripot joint spider (2) and the shaft.
7. Remove and discard the trilobal tripot bushing (3) from the housing (1).





8. Remove and discard the lower spacer ring (1) from the groove (5) on the shaft.
9. Slide tripot joint spider assembly (2) off of the shaft.
10. Remove and discard the second spacer ring (3) from the shaft.
11. Clean the following items with cleaning solvent:
^ The tripot balls
^ The needle rollers
^ The housing
12. Remove all traces of old grease and any contaminates. Dry all parts.





13. Inspect the following parts for damage or wear:
^ The tripot joint spider assembly (2)
^ The housing (1)
^ The needle rollers

Assembly Procedure





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 shaft.
2. Position the small end of the joint boot (1) into the joint boot groove (3) on the shaft.





3. Mount DT-47732 in a vise and proceed as follows:
1. Position the inboard end (1) of the wheel driveshaft assembly in tool DT-47732.
2. Align the top of boot neck on the bottom die using the indicator.
3. Place the top half of tool DT-47732 on the lower half of tool.
4. Before proceeding, ensure there are no pinch points on the wheel driveshaft inboard boot. This could cause damage to the inboard boot.
5. Insert the bolts (2).
6. Tighten the bolts by hand until snug.





Notice: Refer to Fastener Notice in Service Precautions.

4. Align the following items:
^ The inboard boot (1)
^ The shaft boot grooves
^ The swage ring (2)

Tighten each bolt of DT-47732 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.





5. Install the spacer ring (2) on the shaft (1) in groove using J 8059.





6. Slide the tripot joint spider assembly (3) toward the spacer ring (1) as far as it will go on the shaft (4).
7. Install the shaft retaining ring (2) in the groove of the shaft (4).





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.
10. Position the larger new boot 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 inboard boot (2), with the larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove.

Important: The inboard boot must not be dimpled, stretched out or out of shape in any way. If the inboard boot is not shaped correctly, 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. Shape the inboard boot properly by hand. Remove the tool.

13. Position the joint assembly at dimension a = 107 mm (4.21 inch).





14. Align the following items while latching:
^ The seal (3)
^ The tripot housing (2)
^ The large seal retaining clamp

Crimp the seal retaining clamp with J 35910 to 176 Nm (130 ft. lbs.). Add the breaker bar (5) and the torque wrench (4) to J 35910 if necessary.
^ Verify dimension a = 2.15 mm (0.085 inch).
15. Fully stroke the joint several times to disperse the grease.