Wheel Drive Shaft Inner Joint and Boot Replacement

Wheel Drive Shaft Inner Joint and Boot Replacement

Tools Required
* J 8059 Snap Ring Pliers
* J 35566 Drive Axle Seal Clamp Plier
* J 41048 Drive Axle Swage Ring Clamp Tool

Disassembly Procedure




1. Remove the clamp from the boot with a pair of side cutters.

Important: Do not damage the tripot housing (1).


2. Use a hand grinder to cut through the swage ring.
3. Remove the tripot housing (1) and the trilobal tripot bushing (2) from the halfshaft bar (5).
4. Thoroughly degrease the housing (1) and the spider assembly.
5.
Discard the tripot bushing.
6. Use 320 grit 3M cloth, or equivalent, to remove any evident corrosion in the transmission sealing surface.
7. Allow the housing (1) and the spider assembly to dry.





Important: Handle the tripot spider assembly (1) with care. Tripot balls and needle rollers may separate from the spider trunnion if the tripot balls and needle rollers are not handled carefully.


8. Compress the tripot boot (4) onto the halfshaft bar (3), away from the spider assembly (1).




9. Spread the spacer rings (1, 3) using J 8059, or equivalent, to remove the spider assembly (2).




10. Remove the following items:

* The spacer ring (1)
* The spider assembly (2)
* The second spacer ring (3)
* The tripot boot (4)

11. Discard the tripot boot and spacer rings.
12. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area grooves.
13. Inspect the following items:

* The needle rollers
* The needle bearings
* The trunnion

14. Inspect the tripot housing for unusual wear, cracks, or other damage.
15. Use the appropriate kit to replace any damaged parts.

Assembly Procedure




1. Position the new swage clamp onto the neck of the boot. Do not swage.
2. Slide the new small swage clamp (2) and the boot (1) to the proper position on the halfshaft bar (3).




3. Position the neck of the boot in the boot groove on the halfshaft bar.
4. In order to swage the swage clamp, position the inboard end (1) of the halfshaft assembly in J 41048.




5. Align the swage clamp (2) within J 41048.




6. Place the top half of the J 41048 on the bottom half.
7. Inspect to make sure there are no pinch points on the boot before proceeding.
8. Insert the bolts (2).
9. Tighten the bolts (2) by hand until snug.

Notice: Refer to Fastener Notice (Fastener Notice).

10. Align the following items:

* The boot
* The halfshaft bar
* The swage clamp

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

11. Loosen the bolts.
12. Separate the dies.

Important: If deformities exist in the swage clamp, place the swage clamp back into J 41048. Ensure the swage clamp covers the whole swaging area. Re-swage the swage clamp.


13. Inspect the swage clamp for any "lip" deformities.





Important: Assemble the joint with the convolute retainer in the correct position. Assemble the joint to meet the specified dimension to avoid boot damage.


14. Install the convolute retainer over the boot capturing 4 convolutions.





Important: Ensure that the rings are fully seated.


15. Install the spacer ring (2) and spider assembly (1) onto the halfshaft bar (3).
16. Install the other spacer ring in the groove at the end of the halfshaft bar. Ensure that the rings are fully seated.




17. Pack the boot and housing with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
18. Place the large retaining clamp (2) on the boot.
19. Place the housing (1) and the new trilobal tripot bushing over the spider assembly (3).
20. Install the boot onto the trilobal tripot bushing.




21. Inspect the inboard stroke position (see diagram).

* For male tripot housing assembly: dimension a = 280 mm (11 in).
* For female tripot housing assembly: dimension b = 228 mm (9 in).




22. Secure the large retaining clamp (2) and the boot (3) to the housing (1) using J 35566.




23. Remove the convolute retainer from the boot (1).