Front Wheel Drive Shaft Outer Joint Boot Replacement

Front Wheel Drive Shaft Outer Joint Boot Replacement

Special Tools

DT 35910 - Drive Axle Seal Clamp Pliers

For equivalent regional tool, refer to Special Tools Tools and Equipment.

Disassemble Procedure

1. Remove the wheel drive shaft from the vehicle. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.




2. Install the drive axle shaft in a soft jawed vice.





Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.

3. Use a flat-bladed tool, remove the boot clamp (2) from the constant velocity (CV) joint (1) and the boot (3).
4. Using a pair of side cutters, remove the boot clamp (4) from the boot (3) and the wheel drive shaft (5).
5. Discard the boot clamps (2) and (4). Use NEW clamps only.




6. Using a block of wood and a hammer, remove the CV joint (2) from the wheel drive shaft (1).




7. Remove the boot (1) from the wheel drive shaft (2).

Note: If any sign of damage or excessive wear, replace the wheel drive shaft as any assembly. There are no service parts available for the outer joint assembly.

8. Inspect the outer CV joint for damage and wear. Refer to Wheel Drive Shaft Outer Joint Inspection Wheel Drive Shaft Outer Joint Inspection.

Assemble Procedure




1. Position the boot and the clamp (1) on the wheel drive shaft (2).




2. Ensure that the boot (1) is properly seated in the grooved (2) wheel drive shaft (3).
3. Place approximately 95 grams (3.4 ounces) of lubricant inside the outboard boot and pack the CV joint with the remaining lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers [1][2]Axle Shaft Assembly.




4. Using a block of wood and a hammer, install the CV joint (1) on the wheel drive shaft.




5. Install the boot clamp (2) on the CV joint housing (1).





Note: Ensure that the boot clamp is properly positioned around the entire circumference of the boot.

6. Using the DT 35910 - pliers with a breaker bar and a ratchet wrench (1), tighten the boot clamp (2) until the gap (3) in the boot clamp measure 1.6 mm (0.06 in).




7. Using the DT 35910 - pliers (3), breaker bar (5), and the torque wrench or ratchet wrench (4), tighten the boot clamp (1) until the gap (6) in the boot clamp measure 2.0 mm (0.08 in).
8. Distribute the lubricant within the outer CV joint by moving it in a circular motion at least four to five times.
9. Remove the wheel drive shaft from the bench vise.
10. Install the wheel drive shaft assembly. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.