Wheel Drive Shaft Inner Joint and Boot Replacement

Disassembly Procedure

^ Tools Required
- J 8059 Snap Ring Pliers





1. Disconnect the swage ring from the halfshaft bar using a hand grinder to cut through the ring taking care not to damage the halfshaft bar.

Important: Do not cut through the halfshaft inboard boot and damage sealing surface of the outer housing (1) and the trilobal tri-pot bushing (3).

2. Remove the large boot retaining clamp (2) from the tri-pot joint with side cutters. Discard the large boot retaining clamp (2).
3. Separate the halfshaft inboard boot from the trilobal tri-pot bushing (3) at the large diameter.
4. Slide the boot away from the joint along the halfshaft bar.





5. Remove the housing (1) from the tri-pot joint spider and the halfshaft bar (2).





6. Spread spacer ring (2) using J8059.





7. Slide the spacer ring (3) and the tri-pot joint spider (2) back on the halfshaft bar (4).
8. Remove the halfshaft bar retaining ring (1) from the groove on the halfshaft bar.
9. Slide tri-pot joint spider assembly (2) off of the halfshaft bar (4).
10. Clean the tri-pot joint spider assembly (2) and the housing thoroughly with cleaning solvent.
11. Remove all traces of old grease and any contaminates. Dry all the parts.
12. Remove the trilobal tri-pot bushing from the housing.
13. Remove the spacer ring (3) and the boot from the halfshaft bar (4).
14. Inspect the following parts for damage or wear:
^ The halfshaft inboard boot
^ The tri-pot joint spider assembly (2)
^ The housing
^ The trilobal tri-pot bushing


Assembly Procedure

^ Tools Required
- J 41048 Swage Tool
- J 8059 Snap Ring Pliers
- J 35910 Seal Clamp Tool





1. Install the new swage ring (2) on the neck of the halfshaft inboard boot (1). Do not swage.
2. Slide the halfshaft inboard boot (1) onto the halfshaft bar.
3. Position the neck of the halfshaft inboard boot (1) in the boot groove (3) on the halfshaft bar.





4. Position the inboard end of the halfshaft assembly (1) using J 41048.





5. Align the swage ring (2) by performing the following steps:

Important: Before proceeding, ensure there are no pinch points on the halfshaft inboard boot (1). This could cause damage to the halfshaft inboard boot (1).

5.1. Place the top half of J 41048 on the lower half of J 41048.
5.2. Insert the bolts.
5.3. Tighten the bolts by hand until snug.

Notice: Refer to Fastener Notice in Service Precautions.

Important: Align the following items:
^ The halfshaft inboard boot (1)
^ The housing
^ The swage ring (2)

Tighten Each bolt 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.

5.4. Loosen the bolts.
5.5. Separate the dies.
5.6. Check the swage ring (2) for any "lip" deformities. If present, place the ring (2) back into the J 41048 ensuring the swage ring (2) covers the whole swaging area.
5.7. Re-swage the swage ring (2).





6. Install the spacer ring (3) on the halfshaft bar (4) and beyond the second groove.

Important: Ensure that the counterbored face of the tri-pot joint spider (2) faces end of the halfshaft bar (4).

7. Slide the tri-pot joint spider assembly (2) toward the spacer ring (3) as far as it will go on the halfshaft bar (4).
8. Install the halfshaft bar retaining ring (1) in the groove of the halfshaft bar (4) using J 8059.
9. Slide the tri-pot joint spider assembly (2) towards the end of the halfshaft bar (4).
10. Reseat the spacer ring (1) in the groove on the halfshaft bar (4).
11. Place approximately half of the grease from the service kit in the halfshaft inboard boot. Use the remainder of the grease to repack the housing.
12. Install the trilobal tri-pot bushing to housing. Ensure the trilobal tri-pot bushing is flush with the face of the housing.
13. Position the larger new clamp on the halfshaft inboard boot.
14. Slide the housing over the tri-pot joint spider assembly on the halfshaft bar.
15. Slide the large diameter of the halfshaft inboard boot, with the larger clamp in place, over the outside of the trilobal tri-pot bushing and locate the lip of the boot in the groove.





Important: The halfshaft inboard boot (2) must not be dimpled, stretched out or out of shape in any way. If the halfshaft inboard boot (2) is not shaped correctly, carefully insert a thin flat blunt tool (no sharp edges) between the large boot opening and the trilobal tri-pot bushing to equalize the pressure. Shape the halfshaft inboard boot properly by hand. Remove the tool.

16. Position the joint assembly at the proper vehicle dimension.





Important: Align the following items while latching:
^ The halfshaft inboard boot
^ The housing (2)
^ The large boot retaining clamp (3)

17. Crimp the boot retaining clamp (3) with J 35910.