Wheel Drive Shaft Outer Joint and Boot Replacement (With WL9)
Wheel Drive Shaft Outer Joint and Boot Replacement (With WL9)
Special Tools
* DT-48267 - Drive Axle Swage Ring Clamp
* J 8059 - Snap Ring Pliers
* J 35910 - Drive Axle Seal Clamp Pliers
For equivalent regional tools, refer to Special Tools Tools and Equipment.
Removal Procedure
1. Clamp the wheel drive shaft (1) 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.
2. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the seal retaining clamp.
Use a hand grinder to cut through the swage ring in order to remove the swage ring.
3. Remove the small eared clamp with a side cutter. Discard the eared clamp.
4. Separate the wheel drive shaft outboard seal from CV joint outer race (1) at large diameter.
5. Slide the seal (4) away from joint along wheel drive shaft (5).
6. Wipe the grease from the face of the CV joint inner race (3).
7. Spread the ears on the race retaining ring (2) using J 8059 - pliers (6).
8. Remove the CV joint assembly (1) from the wheel drive shaft (5).
9. Remove the wheel drive shaft outboard seal (4) from the wheel drive shaft (5).
10. Discard the old outboard seal (4).
11. Place a brass drift against the CV joint cage (1).
12. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
13. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts.
14. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2).
15. Repeat this process to remove all 6 of the balls.
16. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (2). At the same time, align the cage windows (3) with the lands of the outer race.
17. Lift out the cage (4) and the inner race.
18. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward.
Note: Remove all traces of old grease and any contaminates
19. Clean the following items thoroughly with cleaning solvent.
* The inner and outer race assemblies
* The CV joint cage
* The chrome alloy balls
20. Dry all the parts.
21. Check the CV joint assembly for the following items:
* Unusual wear
* Cracks
* Damage
22. Replace any damaged parts.
23. Using a wire brush, remove any rust in the seal mounting area (grooves) in the wheel drive shaft.
Installation Procedure
Note: For eared clamp, place a towel in the vise before inserting the wheel drive shaft.
1. For eared clamp installation, mount the wheel drive shaft into a vise.
Note: Do not swage or crimp.
2. Install the new swage ring or eared clamp (2) on the neck of the outboard seal (1).
3. Slide the outboard seal (1) onto the wheel drive shaft and position the neck of the outboard seal (1) in the seal groove on the wheel drive shaft. The largest groove below the sight groove on the wheel drive shaft is the seal groove (3).
Note: For eared clamp installation, proceed to step 7.
4. For swage ring installation use DT-48267 - clamp in the following way:
1. Position the outboard end of the wheel drive shaft assembly (1) in DT-48267 - clamp.
2. Align the swage ring.
3. Place the top half of DT-48267 - clamp.
Note: Align the following items during this procedure:
* The outboard seal (1)
* The wheel drive shaft
* The swage ring
4. Install the bolts (2) and tighten by hand.
Note: Alternate between each bolt until both sides are bottomed.
5. Using the proper size socket and ratchet wrench, tighten the bolts (2) 180 degrees until bottom.
5. Loosen the bolts and separate the dies.
6. Check swaged ring (2) for any lip deformities. If present, place the ring (2) back into the DT-48267 - clamp making sure the ring covers the whole swaging area. If necessary, re-swage the ring.
Caution: Refer to Fastener Caution Fastener Caution.
7. Crimp the eared clamp (1) using the J 35910 - pliers, a breaker bar, and a torque wrench.
Tighten the eared clamp to 136 Nm (100 lb ft).
8. Check the gap dimension, continue tightening until the gap dimension is reached.
9. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race.
10. Hold the inner race 90 degrees to centerline of cage with the lands of the inner race (1) aligned with the windows of the cage (2) and insert the inner race into the cage.
11. Hold the cage and the inner race 90 degrees to centerline of the outer race (1) and align the cage windows (3) with the lands of the outer race.
Note: Be sure that the retaining ring side of the inner race faces the wheel drive shaft.
12. Place the cage and the inner race into the outer race.
13. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball.
14. Repeat this process until all 6 balls are in place.
15. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease.
16. Push the CV joint (2) onto the wheel drive shaft (1) until the retaining ring is seated in the groove on the wheel drive shaft (1).
Note: The outboard seal (1) must not be dimpled, stretched or out of shape in any way. If the outboard seal (1) is not shaped correctly, equalize the pressure in the outboard seal (1) and shape the seal properly by hand.
17. Slide large diameter of the outboard seal (1) with the large seal retaining clamp (2) in place over the outside of the CV joint outer race (3) and locate the seal lip in the groove on the CV joint outer race.
18. Using the J 35910 - pliers (3) and the torque wrench (2), tighten the seal retaining clamp (1) to 174 Nm (130 lb ft)..
19. Check the gap dimension (4) on the clamp ear. Continue tightening until the gap dimension is reached. Dimension 1.9 mm (5/64 in).