Constant Velocity Joint: Service and Repair

DISASSEMBLY
Follow disassembly steps outlined in the illustration noting the following.
1. After removing the Tripod Joint (T.J.) case from the Birfield Joint (B.J.) assembly, wipe off the grease on the T.J. case.





2. Use the special tool to remove the inner shaft assembly, together with the seal plate, from the T.J. case.





3. Use the special tools to remove the inner shaft from the bracket.





4. Use special tools to remove center bearing.





5. Remove the snap ring from the drive shaft with the snap ring plier.
6. Take out the spider assembly from the drive shaft.
7. Clean the spider assembly.

CAUTION:
- Do not disassemble the spider assembly.
- Use care in handling so as not to damage the drive shaft.

8. Wipe the grease off of the spline portion.
9. Remove the T.J. boot.

NOTE: If the boot is reused, wrap plastic tape around the drive shaft spline so that the boot is not damaged when it is removed.

INSPECTION
- Check the drive shaft for damage, bending or corrosion.
- Check the inner shaft for damage, bending or corrosion.
- Check the drive shaft splines for wear or damage.
- Check the inner shaft splines for wear or damage.
- Check the spider assembly for roller rotation, wear or corrosion.
- Check the groove inside T.J. case for wear or corrosion.
- Check the boots for deterioration, damage or cracking.
- Check the center bearing for seizure, discoloration or roughness of rolling surface.
- Check the dust cover for damage or deterioration. Check the dynamic damper for damage or cracking.

ASSEMBLY
Follow disassembly in reverse order for assembly, noting the following.





1. Install the dynamic damper in the position shown in the illustration (A) for the right side is 374 +/-3 mm (14.72 +/-0.12 inches) and 194 +/-3 mm (7.64 +/-0.12 inches) for the left side with manual transmission.
2. Wrap plastic tape around the spline part on the drive shaft, and then install the T.J. boot band and T.J. boot.





3. Apply the specified grease furnished in the repair kit to the spider assembly between the spider axle and the roller.

CAUTION:
- The drive shaft joint uses special grease. Do not mix old and new or different types of grease.
- If the spider assembly has been cleaned, take special care to apply the specified grease.

4. Install the spider assembly to the shaft from the direction of the spline bevelled section.

NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.

CAUTION: The drive shaft joint uses special grease. Do not mix old and new or different types of grease.





5. Use special tools to install center bearing.





6. Apply the MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent to the rear surfaces of all dust seals. Inner dust seal 7 - 10 grams (0.25 - 0.35 oz.) Outer dust seal 4 - 6 grams (0.14 - 0.21 oz.).





7. Use the special tools to install the dust seal so that its surface runs even with that of the center bearing bracket.
8. Apply the MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent to the lip of each dust seal.

NOTE: When applying grease, make sure that it does not adhere to anything outside the lip.





9. Use special tool to install the inner shaft.





10. Apply MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent to the inner shaft spline, then press fit into the T.J. case.





11. Use the special tool secure the T.J. case
12. Use a pipe with a diameter of 30 mm (1.18 inch) to press the seal plate into the T.J. case.





13. Fill the Repair kit grease 105 grams (3.70 oz.) furnished in the repair kit to the T.J. case.

NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.

CAUTION: The drive shaft joint uses special grease. Do not mix old and new or different types of grease.





14. Set the T.J. boot bands at (A) 80 +/-3 mm (3.15 +/-0.12 inch) in order to adjust the amount of air inside the T.J. boot, and then tighten the T.J. boot band securely.