1. Clamp the halfshaft assembly into a vise which has non-marring inserts.
2. Remove the large boot retaining clamp from the outboard cross groove joint with a side cutter.
3. Discard the large boot retaining clamp.
4. Remove the small boot retaining clamp (4) from the halfshaft bar (1) with side cutter.
5. Discard the small boot retaining clamp (4).
6. Wipe grease from face of cross-groove outer race (3).



7. Use a brass drift and a hammer to tap on the outer race of the cross groove (3). This may take several taps before the cross groove assembly (3) disconnects from the halfshaft bar (1). Take care not to damage the inner race (4).

Important: Never reuse the retaining ring (5).

8. Remove the retaining ring (5) from the haflshaft bar (1).
9. Discard the retaining ring (5).
10. Remove the old boot (2) from the halfshaft bar (1).
11. Discard the old boot (2).
12. Check the inboard joint for any visible damage or wear. Replace if necessary.

Tools Required

J 35910 Drive Alxe Seal Clamp Pliers

1. Pack the outboard cross groove joint with half the grease provided in the service kit.
2. Place new small boot retaining clamp on neck of boot. Do not crimp.
3. Position the new large boot retaining clamp around the joint boot.
4. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves).
5. Place the new retaining ring onto the halfshaft bar.
6. While supporting the inboard assembly, place the halfshaft assembly onto the arbor press with the outboard cross groove assembly under the press head.
7. Lower the arbor press head onto the outboard cross groove assembly until the press cannot move any further.
8. Remove the halfshaft assembly from the arbor press.
9. Slide the boot back toward the outboard joint and place the neck of the joint boot into the boot groove on the halfshaft bar.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

10. Crimp the small retaining clamp by using J 35910 with a breaker bar (3) and torque wrench (2).

Tighten
Tighten the clamp to 136 N·m (100 lbs ft).

11. Check the gap dimensions. Continue tightening until the gap correct dimension is reached.
12. Place the remaining grease into the outboard boot.

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

13. Slide large diameter of the boot with the large boot retaining clamp in place over the lip of the inboard joint housing.



14. Crimp the large boot retaining clamp by using J 35910 with a breaker bar (2) and torque wrench (1).

Tighten
Tighten the clamp to 176 N·m (130 lbs ft).

15. Check the gap dimensions. Continue tightening until the gap correct dimension is reached.