Wheel Drive Shaft Outer Joint and Boot Replacement

Disassembly Procedure

^ Tools Required
- J8059 Snap Ring Pliers
- J 35910 Seal Clamp Tool
- J 41048 Small Swage Tool





1. Remove the large boot retaining clamp from the CV joint with a side cutter. Discard the boot retaining clamp.

Important: Take care when using the hand grinder to avoid damage to the halfshaft bar. Use a hand grinder to cut through the swage ring in order to remove the swage ring.

2. Separate the halfshaft outboard boot from CV joint outer race (1) at large diameter.
3. Slide the boot (5) away from joint along halfshaft bar (4).
4. Wipe the grease from the face of the CV joint inner race (2).





5. Spread the ears on the race retaining ring (3) with J 8059.
6. Remove the CV joint assembly (1) from the halfshaft bar (4).
7. Remove the halfshaft outboard boot (5) from the halfshaft bar (4).
8. Discard the old outboard boot.





9. Place a brass drift against the CV joint cage (1).
10. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
11. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts.
12. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2).
13. Repeat this process to remove all six of the balls.





14. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows with the lands of the outer race.
15. Lift out the cage (4) and the inner race.





16. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward.
17. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.
^ The inner and outer race assemblies
^ The CV joint cage
^ The chrome alloy balls
18. Dry all the parts.
19. Check the CV joint assembly for the following items:
^ Unusual wear
^ Cracks
^ Damage
20. Replace any damaged parts.
21. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves).


Assembly Procedure

^ Tools Required
- J 41048 Small Swage Tool
- J 35910 Seal Clamp Tool





1. Install the new swage ring (2) on the neck of the halfshaft outboard boot (1). Do not swage.
2. Slide the halfshaft outboard boot (1) onto the halfshaft bar and position the neck of the halfshaft outboard boot (1) in the boot groove on the halfshaft bar. The largest groove below the sight groove on the halfshaft bar is the boot groove (3).





3. The swage ring is swaged using J 41048 by the following method:
3.1. Position the outboard end of the halfshaft assembly (1) in J 41048.
3.2. Align the swage ring.
3.3. Place the top half of J 41048 on the lower half of J 41048.
3.4. Make sure there are no pinch points on the halfshaft outboard boot before proceeding. This could cause damage to the halfshaft outboard boot.

Important: Align the following items during this procedure:
^ The halfshaft outboard boot (1)
^ The housing
^ The swage ring

Notice: Refer to Fastener Notice in Service Precautions.

3.5. Insert the bolts (2) and tighten by hand until snug.
^ Each bolt 180° at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.





4. Loosen the bolts and separate the dies.
5. Check swaged ring (2) for any "lip" deformities. If present, place the ring (2) back into the J 41048 making sure the ring covers the whole swaging area. Then re-swage the ring.





6. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race.
7. Hold the inner race 90° 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.





8. Hold the cage and the inner race 90° to centerline of the outer race (1) and align the cage windows (3) with the lands of the outer race.

Important: Be sure that the retaining ring side of the inner race faces the halfshaft bar.

9. Place the cage and the inner race into the outer race.
10. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball.
11. Repeat this process until all six balls are in place.
12. Place approximately half the grease from the service kit inside the halfshaft outboard boot and pack the CV joint with the remaining grease.





13. Push the CV joint (2) onto the halfshaft bar (1) until the retaining ring is seated in the groove on the halfshaft bar.





Important: The halfshaft outboard boot (1) must not be dimpled, stretched or out of shape in any way. If the halfshaft outboard boot (1) is not shaped correctly, equalize the pressure in the halfshaft outboard boot (1) and shape the boot properly by hand.

14. Slide large diameter of the halfshaft outboard boot (1) with the large boot retaining clamp (2) in place over the outside of the CV joint outer race (3) and locate the boot lip in the groove on the CV joint outer race.





15. Crimp the boot retaining clamp (3) using J 35910.
^ Crimp the clamp (3) to 174 Nm (130 ft. lbs.).