Tools Required

J 8059 Snap Ring Pliers

Important: Do not cut through the drive axle inboard seal (4) and damage sealing surface of the outer housing (1) and the trilobal tripot bushing (2).

1. Remove the larger seal retaining clamp from the tripot joint with side cutter and dispose.
2. Disconnect the small seal retaining clamp from the axle shaft using a hand grinder to cut through the ring taking care not to damage the axle shaft.
3. Use a hand grinder in order to remove the swage ring. Take care not to damage the axle shaft.
4. Separate the drive axle inboard seal (4) from the trilobal tripot bushing (2) at the large diameter.
5. Slide the seal away from the joint along the axle shaft (3).



6. Remove the housing (1) from the tripot joint spider (2) and the axle shaft.



7. Spread spacer ring (1) using J 8059 .
8. Slide the spacer ring (1) and tripot joint spider back on axle shaft (2).
9. Remove the axle shaft retaining ring from the groove on the axle shaft (2).



10. Slide tripot joint spider assembly (1) off of the axle shaft (3).
11. Remove the spacer ring (4) and the drive axle inboard seal from the axle shaft (3).
12. Clean the following items thoroughly with cleaning solvent:

•	The bearing blocks (2)

•	The tripot joint spider assembly (1)

•	The housing

13. Inspect the following parts for damage or wear:

•	The drive axle inboard seal

•	The tripot joint spider assembly (1)

•	The housing

•	The trilobal tripot bushing

•	The bearing blocks (2)

Tools Required

1. Install the new swage ring (2) on the neck of the drive axle inboard seal (1). Do not swage.
2. Slide the drive axle inboard seal (1) onto the axle shaft.
3. Position the neck of the drive axle inboard seal (1) in the seal groove (3) on the axle shaft.



4. Swage the swage ring using J 41048 by the following method:
5. Position the inboard end of the halfshaft assembly (1) using J 41048 .



6. Align the swage ring (2).
7. Place the top half of J 41048 on the lower half of J 41048 .

Important: Before proceeding, ensure there are no pinch points on the drive axle inboard seal. This could cause damage to the drive axle inboard seal.

8. Insert the bolts.
9. Tighten the bolts by hand until snug.
10. Align the following items:

•	The drive axle inboard seal (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.

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



15. Install the spacer ring (1) on the axle shaft (2) and beyond the second groove.



16. Apply a small amount of grease to the inside of the bearing blocks prior to reassembly.
17. Align the flats on the opening in the bearing block (1) with flats on the spider trunnion (2).
18. Attach the bearing block (1) to the spider trunnion (2).
19. Rotate the block (1) 90 degrees to spider.




Important: Ensure that the counterbored face of the tripot joint spider faces end of the axle shaft.

20. Slide the spider assembly (2) against the spacer ring (4) on the axle shaft (3).
21. Slide the tripot joint spider assembly (2) toward the spacer ring (4) as far as it will go on the axle shaft (3).
22. Install the axle shaft retaining ring (1) in the groove of the axle shaft using J 8059 .
23. Slide the tripot joint spider assembly (2) towards the end of the axle shaft (3).
24. Reseat the spacer ring in the groove on the axle shaft.
25. Place approximately half of the grease from the service kit in the drive axle inboard seal. Use the remainder of the grease to repack the housing.



26. Place a slotted six inch square piece of sheet metal (2) between the drive axle inboard seal (1) and the bearing blocks (3) in order to maintain the proper bearing block alignment during reassembly.
27. Install the trilobal tripot bushing to housing.
28. Position the larger new clamp on the drive axle inboard seal.
29. Slide the housing over the tripot joint spider assembly on the axle shaft.
30. Remove the slotted sheet metal plate (2).
31. Slide the large diameter of the drive axle inboard seal, with the larger clamp in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.




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

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




Important: Align the following items while latching:

1. The drive axle inboard seal (3)
2. The housing (1)
3. The large seal retaining clamp (2)
33. Latch the seal retaining clamp (2) with J 35566 .