Wheel Drive Shaft Inner Joint and Boot Replacement

REMOVAL PROCEDURE

- J 8059 Snap Ring Pliers

NOTICE: With removal of the halfshaft for any reason, the transmission sealing surface (the tripot male/female shank of the halfshaft) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent. Transmission fluid may be used to clean off any remaining debris. The surface should be wiped dry and the halfshaft 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 seal retaining clamp from the tripot joint with side cutter.
3. Dispose of the large seal retaining clamp.

NOTICE: Do not cut through the drive axle inboard seal and damage sealing surface of the outer housing and the trilobal tripot bushing.

4. Separate the drive axle inboard seal from the trilobal tripot bushing (3) at the large diameter.
5. Slide the seal (4) away from the joint along the axle shaft.
6. Remove the housing (1) from the tripot joint spider (2) and the axle shaft.
7. Remove the trilobal tripot bushing (3) from the housing (1).
8. Spread spacer ring (2) with J 8059.





9. Slide the spacer ring and tripot joint spider back on axle shaft (1).





10. Remove the axle shaft retaining ring from the groove (5) on the axle shaft.
11. Slide tripot joint spider assembly (2) off of the axle shaft.
12. Clean the following items with cleaning solvent:
^ the tripot balls
^ the needle rollers
^ the housing

13. Remove all traces of old grease and any contaminates. Dry all parts.





14. Inspect the following parts for damage or wear:
^ the drive axle inboard seal (4)
^ the tripot joint spider assembly (2)
^ the housing (1)
^ the trilobal tripot bushing (3)
^ the needle rollers

INSTALLATION PROCEDURE

- J 35910
- J 41048
- J 36652
- J 36652





1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the small seal clamp (2) onto the axle shaft.
2. Position the small end of the joint seal (1) into the Joint seal groove (3) on the axle shaft.





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 seal neck on the bottom die using the indicator.
3.3. Place the top half of the J 41048 on the lower half of the J 41048.
3.4. Before proceeding, ensure there are no pinch points on the drive axle inboard seal. This could cause damage to the drive axle inboard seal.
3.5. Insert the bolts (2).
3.6. Tighten the bolts by hand until snug.





4. Align the following items:
^ the drive axle inboard seal (1)
^ the housing
^ the swage ring (2)
- Tighten each bolt of J 41048180 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 axle shaft (1) and beyond the second groove using J 8059.

IMPORTANT: Ensure that the counterbored face of the tripot joint spider (2) faces toward the end of the axle shaft (4).





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





8. Slide the tripot joint spider assembly (1) back towards the end of the axle shaft (3).
9. Reseat the spacer ring (2) in the groove on the axle shaft (3).

IMPORTANT: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).

10. Place approximately half of the grease from the service kit in the drive axle inboard seal. Use the remainder of the grease to repack the housing.





11. Install the trilobal tripot bushing (3) to housing.
12. Position the larger new seal retaining clamp (2) on the drive axle inboard seal.
13. Slide the housing (1) over the tripot joint spider assembly on the axle shaft.





14. Slide the large diameter of the drive axle inboard seal (2), with the larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.

IMPORTANT: The drive axle inboard seal must not be dimpled, stretched out or out of shape in any way. If the drive axle inboard seal is not shaped correctly, carefully insert a thin flat blunt tool (no sharp edges) between the large seal opening and the trilobal tripot bushing in order to equalize the pressure. Shape the drive axle inboard seal properly by hand. Remove the tool,

15. Position the joint assembly at the proper vehicle dimension.





16. Align the following items while latching:
^ The drive axle inboard seal (3)
^ The tripot housing (1)
^ The large seal retaining clamp (2)
^ Crimp the seal retaining clamp (2) with J 35910 to 176 Nm (130 lb ft). Add the breaker bar (5) and the torque wrench (4) to J 35910 if necessary.