Wheel Drive Shaft Inner Joint and Boot Replacement

Disassembly Procedure

^ Tools Required
- J 8059 Snap Ring Pliers





1. Remove the clamps from the boot with a pair of side cutters.

Important: Do not damage the tripot housing (1).

2. Use a hand grinder to cut through the swage ring.
3. Remove the tripot housing (1) and the tripot trilobal bushing (2) from the halfshaft bar (5).
4. Wipe the grease off of the tripot assembly roller bearings and the housing (1).
5. Thoroughly degrease the housing (1) and the tripot trilobal bushing (2).
6. Use 320 grit 3M cloth (or equivalent) to remove any evident corrosion in the transmission sealing surface.
7. Allow the housing (1) and the tripot trilobal bushing (2) to dry prior to assembly.





Important: Handle the tripot spider assembly (1) with care. Tripot balls and needle rollers may separate from the spider trunnion if the tripot balls and needle rollers are not handled carefully.

8. Compress the tripot boot (4) onto the halfshaft bar (3), away from the spider assembly (1).





9. Spread the spacer rings using J 8059 (or equivalent) to remove the spider assembly.





10. Remove the following items:
^ The spacer ring (1)
^ The spider assembly (2)
^ The second spacer ring (3)
^ The tripot boot (4)
11. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves).
12. Inspect the following items:
^ The needle rollers
^ The needle bearings
^ The trunnion
13. Check the tripot housing for unusual wear, cracks, or other damage.
14. Replace any damaged parts.









Assembly Procedure

^ Tools Required
- J 41048 wage lamp
- J 35566 Large Seal Retaining Clamp Tool





1. Slide the new small swage clamp (2) and the boot (1) to the proper position (3) on the halfshaft bar.





2. Install the new swage clamp onto the neck of the boot. Do not swage.
3. Position the neck of the boot in the boot groove on the halfshaft bar.
4. In order to swage the swage clamp, position the inboard end (1) of the halfshaft assembly in J 41048.





5. Align the swage clamp (2) within J 41048.





6. Place the top half of the J 41048 on the bottom half.
7. Check to make sure there are no pinch points on the boot before proceeding.
8. Insert the bolts (2).
9. Tighten the bolts (2) by hand until snug.
10. Align the following items:
^ The boot
^ The housing
^ The swage clamp
^ Tighten Each bolt 180 degrees at a time, using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
11. Loosen the bolts.
12. Separate the dies.

Important: If deformities exist in the swage clamp, place the swage clamp back into J 41048. Ensure the swage clamp covers the whole swaging area. Re-swage the swage clamp.

13. Check the swage clamp for any "lip" deformities.





Important: Assemble the joint with the convolute retainer in the correct position. Assemble the joint to meet the specified dimension to avoid boot damage.

14. Install the convolute retainer over the boot capturing four convolutions.





Important: Ensure that the rings are fully seated.

15. Install the spacer ring (2) and spider assembly (1) onto the halfshaft bar (3).
16. Install the other spacer ring in the groove at the end of the halfshaft bar. Ensure that the rings are fully seated.





17. Pack the boot and housing with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
18. Place the large retaining clamp (2) on the boot.
19. Place the housing (1) and the tripot trilobal bushing over the spider assembly (3).
20. Install the boot onto the tripot trilobal bushing.





21. Check the inboard stroke position.





22. Secure the large retaining clamp (2) and the boot (3) to the housing (1) using J 35566.





23. Remove the convolute retainer from the boot (1).