Disassembly

DISASSEMBLY

NOTICE: Use soft metal or wood in between vice jaws to protect the shaft.





1. Clamp the drive axle shaft in a vice.
2. Remove outer CV joint and joint boot.





2.1. Use a hammer and chisel or a flat blade screw driver to disengage outer band from inner band at retainer peg on both large and small boot clamps and discard clamps.
2.2. Separate joint boot from CV joint race at large diameter and slide boot away from joint along axle shaft.
2.3. Wipe excess grease from face of CV inner race.





2.4. Using a rubber mallet, or block of wood and hammer, carefully tap on CV joint to remove from axle.
2.5. Remove boot from axle shaft.
3. Disassemble CV joint.





3.1. Using a brass drift, gently tap on cage until tilted enough to remove first ball.
3.2. Remove remaining balls in similar manner.
3.3. With all balls removed, pivot cage and inner race at 90 degrees to center line of outer race with cage windows aligned with lands of outer race, lift out cage and inner race.
3.4. Rotate inner race up and out of cage.
3.5. Thoroughly degrease all CV joint parts and allow to dry prior to assembly.
4. Assemble CV joint.
4.1. Inspect parts for unusual wear, cracks and other damage. Replace joint assembly if needed.
4.2. Put a light coat of recommended grease on inner and outer race grooves.
4.3. Insert and rotate inner race into cage.
4.4. Install cage and inner race into outer race with windows of cage aligned with lines of outer race.
4.5. Install balls using a brass drift to gently rotate and position cage and inner race.
4.6. Pack assembled joint with grease provided in service kit. (The amount of grease supplied with service kits has been pre-measured for each application.)
5. Remove tri-pot joint and joint boot.





5.1. Cut eared boot retaining clamp on tri-pot boot with side cutters and discard.
5.2. Remove earless clamp, using a small-blade screwdriver and discard.





5.3. Separate boot from tri-pot housing at large diameter and slide boot away from joint along axle shaft.
5.4. Wipe excess grease from face of tri-pot spider and inside of tri-pot housing.
5.5. Remove tri-pot housing from the spider and shaft.

NOTICE: Handle the tri-pot spider assembly with care. Tri-pot balls and needle rollers may separate from spider trunnions.





5.6. Remove spider retaining ring from groove on axle shaft and slide spider assembly off of shaft.
5.7. Remove boot from axle shaft.
5.8. Thoroughly degrease the housing and allow to dry prior to assembly.