Front Wheel Drive Shaft Inner Joint and Boot Replacement
Front Wheel Drive Shaft Inner Joint and Boot Replacement
Special Tools
* CH-804 - Tensioner
* GE-396 - Snap Ring Pliers
For equivalent regional tools, refer to Special Tools Tools and Equipment.
Removal Procedure
1. Remove the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side Front Wheel Drive Shaft Replacement - Left Side or Front Wheel Drive Shaft Replacement - Right Side Front Wheel Drive Shaft Replacement - Right Side
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.
2. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. Discard the retaining clamp.
3. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp.
4. Separate the inboard seal from the trilobal tripot bushing (3) at the large diameter.
5. Slide the seal away from the joint along the halfshaft bar.
6. Remove the housing (1) from the tripot joint spider and the halfshaft bar (2).
7. Remove the spacer ring (1), spider assembly (2), spacer ring (3) (if equipped) using GE-396 - pliers, and tripot boot (4). DISCARD the boot and rings.
8. Clean the halfshaft bar (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves).
9. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit.
Installation Procedure
Note:
Place a towel in the vise before inserting the halfshaft.
1. Mount the halfshaft into a vise.
2. Place the new small eared clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the eared clamp (2) onto the halfshaft bar.
3. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.
4. Crimp the eared clamp (1) using the CH-804 - tensioner (1), and a torque wrench. Tighten the eared clamp to 25 Nm (19 lb ft).
5. Install the spacer ring (2) into the groove of the halfshaft bar using
6. Slide the tripot joint spider assembly (4) as far as it will go on the halfshaft bar.
7. Install the spacer ring (2) into the groove of the halfshaft bar, using GE-396 - pliers.
8. Place approximately 150 grams of the lubricant on the boot and the remaining half of the tripod housing. Refer to Adhesives, Fluids, Lubricants, and Sealers [1][2]Axle Shaft Assembly.
Note:
Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).
9. Install the trilobal tripot bushing (3) to housing (1).
10. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal.
11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.
12. Slide the large diameter of the halfshaft inboard seal (2), with larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.
13. Position the joint assembly at the proper vehicle dimension, a = 106 mm (4.00 in).
14. 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. Remove the tool.
15. Crimp the eared clamp (1) using the CH-804 - tensioner (1), and a torque wrench. Tighten the eared clamp to 25 Nm (19 lb ft).
16. Fully stroke the joint several times to disperse the grease.
17. Install the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side Front Wheel Drive Shaft Replacement - Left Side or Front Wheel Drive Shaft Replacement - Right Side Front Wheel Drive Shaft Replacement - Right Side.