Axle Shaft Cleaning and Inspection

REMOVAL

1. Raise and support rear of vehicle, then drain differential lubricant.
2. Remove axle shaft to companion flange attaching bolts, then on Colt Vista Models, remove axle shaft from differential by prying with screwdriver. On Conquest models, use suitable axle puller to remove axle from differential.
3. If necessary, renew axle shaft oil seal.

Fig. 6 Drive axle assembly. Models w/independent rear suspension:

CLEANING & INSPECTION

1. Remove axle shaft boot bands, then remove Double Offset Joint (DOJ) circlip from outer race. Separate axle shaft from DOJ.
2. On Conquest models, proceed as follows:
a. Remove DOJ balls from cage by prying out with screwdriver.
b. Push DOJ cage towards Birfield Joint (BJ), then remove DOJ snap ring from axle shaft and remove inner race and cage from axle shaft.
c. Wrap vinyl tape around axle shaft splines, then remove DOJ and BJ boots. Do not disassemble BJ
3. On Colt Vista models, proceed as follows:
a. Remove snap ring from axle shaft, then the DOJ inner race, cage and balls as a unit.
b. Clean DOJ as a unit in suitable solvent. If balls fall out of DOJ, reinstall them with DOJ outer race.
c. Wrap vinyl tape around axle shaft splines, then remove DOJ and BJ boots.
d. Wipe grease from BJ Do not disassemble BJ
4. On all models, inspect axle shaft for damage, corrosion and bending. Inspect axle splines for wear and damage. Inspect BJ and DOJ for signs of water and dirt entry and replace as necessary.
5. Wrap vinyl tape around DOJ side of axle shaft splines, the slide boots and small boot bands over tape into position.
6. On Conquest models, proceed as follows:
a. Install DOJ cage onto axle shaft in such a way that smaller diameter of cage is installed first.
b. Install circlip on axle shaft, then the DOJ outer race. Install snap ring on axle shaft.
c. Apply grease from repair kit to DOJ inner race and cage, then fit together.
d. Apply grease from repair kit to DOJ ball friction areas and balls, then insert balls in DOJ
e. Apply 1.8-2.8 oz. of repair kit grease to DOJ outer race, then install axle into DOJ outer race.
f. Apply 1.8-2.8 oz. of repair kit grease to DOJ inner and outer race.
g. Install DOJ outer race circlip.
h. Install DOJ boot and secure large end with boot band. Measuring from large boot band, install small boot band 3.1 inches down axle shaft.
i. Pack 3.5-5.3 oz. of repair kit grease into BJ boot, then install boot with boot bands.
j. Wipe off excess grease.
7. On Colt Vista models, proceed as follows:
a. Fill inside of BJ and BJ boot with 3.2-3.3 oz. of repair kit grease, then install BJ boot with boot bands.
b. Apply repair kit grease to DOJ assembly, then install DOJ onto axle shaft and secure with snap ring.
c. Apply repair kit grease to DOJ outer race, then install axle shaft into DOJ and apply more grease. The amount of grease recommended for this operation is 2.3-3.3 oz.
d. Install axle shaft circlip.
e. Install DOJ boot and secure large end with boot band. Measuring from large boot band, install small boot band 3.1 inches down axle shaft.
f. Wipe off excess grease.

INSTALLATION

1. Install dust cover and new circlip on BJ side of axle shaft.
2. Install axle shaft to differential carrier and companion flange.
3. Insert companion flange to axle shaft boots from companion flange side, then install nuts and torque to 36-43 ft. lbs.