Wheel Drive Shaft Inner Joint and Boot Replacement (Without Z06)

Wheel Drive Shaft Inner Joint and Boot Replacement (Without Z06)

Special Tools

* CH 48894 - Wheel Drive Shaft Boot Clamp Pliers

* J 35910 - Drive Axle Seal Clamp Pliers

* J 42572 - Axle Boot Crimp Tool

* J 46588 - Axle Seal Crimp Tool

Note: If the inner joint is found to have excessive wear or damaged inner components, replace the wheel drive shaft as an assembly. The inner joint and it's inner components are not serviced.

Disassemble Procedure

1. Remove the rear wheel drive shaft from the vehicle. Refer to Rear Wheel Drive Shaft Replacement Service and Repair.




2. Wrap a shop towel around the axle shaft.

3. Install the wheel drive shaft horizontally in a bench vise.

4. Using the J 46588 - tool, remove the large seal retaining clamp from the CV joint seal.

5. Using a side cutter, remove and discard the small boot clamp.

6. Remove the boot from the outer joint housing and position the boot down the wheel drive shaft.

Note: Position the wheel drive shaft so that the inner joint is facing up and the outer joint is facing down.

7. Install the wheel drive shaft vertically in the vise.

Note: Insert a small flat-bladed screwdriver between the retaining ring and the outer race

8. Using a flat bladed screwdriver, remove the retaining ring from the outer race.

9. Relocate the retaining ring away from the CV joint.





Note: Use the boot to catch any of the bearings that may fall out of the cage and inner race when the outer race is removed.

10. Remove the outer race from the wheel drive shaft axle.




11. Remove any remaining bearings balls from the cage and inner race.

12. Remove any of the bearing that fell into the boot.




13. Using the J 35910 - pliers, remove the retaining ring from the wheel drive shaft.




14. Align the cage lands with the inner race ball tracks.

15. Reposition the cage along the axle shaft away from the inner race.

16. Remove the lubricant from the inner race.

17. Using the appropriate tool, remove the inner race from the axle shaft.




18. Remove the cage from the wheel drive shaft.




19. Remove the boot from the wheel drive shaft.

20. Remove the wheel drive shaft from the bench vise.

Note: If any of the following components are found to have excessive wear or are damaged, replace the wheel drive shaft as an assembly.

21. Thoroughly clean the following components with the proper cleaning solvent:

* The inner race

* The outer race

* The cage

* The balls

* The axle shaft exposed end

22. Thoroughly air dry all the parts.

Assemble Procedure

Caution:
Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.




1. Wrap a shop towel around the wheel drive shaft

2. Install the wheel drive shaft horizontally in a bench vise.

3. Install the NEW boot and clamp on the wheel drive shaft.





Note: Install the cage so that the smaller diameter of the cage is facing the vise.

4. Install the cage on the wheel drive shaft.





Note: The inner race spline relief must face away from the end of the axle shaft

5. Install the inner race on the wheel drive shaft.

Note: Ensure that the inner race spline relief side is installed on the wheel drive shaft first.

6. Position the inner race splines on the wheel drive shaft.

Note: Ensure that the inner race is fully seated on the heel drive shaft and the retaining ring can be seen.

7. Using a block of wood and a hammer, install the inner race on the wheel drive shaft




8. Using the appropriate tool, install the retaining ring on the wheel drive shaft.

9. Position the cage so the cage lands align with the inner race ball tracks.

10. Install the cage onto the inner race.

11. Position the cage windows to align with the inner race ball tracks.




12. Insert approximately 60 % of the lubricant into the outer race.




13. Position the wheel drive shaft vertically in the bench vise so the inner joint end is up.

14. Apply a small amount of the lubricant to the cage windows and inner race ball tracks.

15. Insert the remaining lubricant into the boot.





Note: Position the retaining ring below the cage toward the vise.

16. Install the outer race retaining ring on the wheel drive shaft.

Note: Use the seal to keep the balls in position if necessary.

17. Install the bearings through the cage windows to the inner race ball tracks.

18. Install the outer race onto the axle shaft.





Note: Be careful not to allow the grease in the outer race to leak out.

19. Align the outer race ball tracks to the balls.

20. Slide the outer race down over the balls.

21. Position the wheel drive shaft horizontally in the bench vise.

22. Slide the outer race toward the vise.

23. Engage the outer race retaining ring.

24. Insert the outer race retaining ring into the groove along the outer edge of the outer race.

25. Position the outer race retaining ring so the opening in the ring aligns with an outer race land (not a ball track).

26. Position the large diameter end of the seal onto the outer race.




27. Position the small boot clamp (3) on the neck of the boot (4).

28. Position the seal and small clamp to the wheel drive shaft (2).

29. Measure the distance (1) between the edge of the seal and the edge of the last axle shaft groove closing edge should be 2.5 mm (0.10 in) adjust fit accordingly.





Note: Ensure that the clamp is securely closed and seated on the boot.

30. Using the CH 48894 - pliers(1), close the boot clamp (3).




31. Adjust the plunging motion of the joint accordingly until the measure the distance (1) between the end of the seal and the end of the joint outer race is 224-228 mm (8.82-8.98 in).




32. Position the large clamp (2) on the boot (3).

33. Position the boot and large clamp to the joint outer race (4) as shown.

34. Adjust the boot until the measure the distance (1) between the edge of the seal and the edge of the joint outer race last groove closing edge is 0.8 mm (0.03 in).

Note: The boot must not be distorted in any way. If the seal is NOT shaped correctly, equalize the pressure in the seal and shape the seal properly by hand.

35. Inspect the seal for proper shape.

Note: If the boot has been cut or punctured during assembly, replace the boot.

36. Inspect the boot for damage.

37. Ensure that the boot is properly seated on the CV joint housing.





Note: Ensure that the clamp is fully engaged in the boot clamp band.

38. Using the J 42572 - tool, lock the boot clamp (3).

39. Remove the wheel drive shaft from the bench vise.

40. Move the CV joint in a circular motion 4 or 5 times to distribute the lubricant with the CV joint.

41. Inspect the inner CV joint and wheel drive shaft for smooth operation.

42. Install the rear wheel drive shaft into the vehicle. Refer to Rear Wheel Drive Shaft Replacement Service and Repair.