Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Sea
Tools Required
Important: Due to the helical splines on the halfshaft bar, disassembly and assembly
of the joints will be difficult. Follow the instructions provided.
- Remove the large seal retaining clamp from the CV joint with a side
cutter. Discard the large seal retaining clamp.
- Remove the small seal retaining clamp from the halfshaft bar with
a side cutter and discard.
- Separate the CV joint seal from the CV joint race (2) at
the large diameter.
- Slide the seal away from the joint along the halfshaft bar.
- Wipe the grease from the face of the CV joint inner race (1).
- Before removing the CV joint assembly from the halfshaft bar,
perform the following procedure:
6.1. | Choose a reference mark (B) on the halfshaft bar. |
6.2. | Measure the distance between the reference mark (B) and
the face of the CV joint inner race (1). Make a note of this measurement.
The measurement is (A). |
- Clamp the halfshaft (1) into a
vise.
- Attach the J 41398
to the threaded area of the outer race (2).
- Attach J 2619-01
onto the outer end of the J 41398
.
- Use the J 2619-01
to remove the
CV joint from the halfshaft bar.
- Remove J 2619-01
and J 41398
from the CV joint.
Important: Never reuse the retaining ring.
- Remove the retaining ring from the halfshaft bar. Discard the retaining
ring.
- Remove the CV joint seal (1) from the halfshaft bar.
- Place a brass drift against the CV joint
cage (1).
- Tap gently on the brass drift with a hammer in order to tilt the
cage (1).
- Remove the first chrome alloy ball (2) when the CV joint
cage (1) tilts.
- Tilt the CV joint cage (1) in the opposite direction to
remove the opposing chrome alloy ball (2).
- Repeat this process to remove all six of the balls.
- Pivot the CV joint cage (4) and
the inner race 90 degrees to the centerline of the outer race (1).
At the same time, align the cage windows with the lands of the outer race (2).
- Lift out the cage (4) and the inner race.
- Remove the inner race (1) from
the cage (2) by rotating the inner race (1) upward.
- Clean the inner and outer race assemblies, the CV joint cage and
the chrome alloy balls thoroughly with cleaning solvent. Remove all traces
of old grease and any contaminates.
- Dry all the parts.
- Check the CV joint assembly for unusual wear, cracks, or other
damage.
- Replace any damaged parts.
- Clean the halfshaft bar. Use a wire brush to remove any rust in
the seal mounting area (grooves).
Tools Required
J 35910 Seal Clamp Tool
- Put a light coat of grease from service
kit on the ball grooves of the inner race and the outer race.
- Hold the inner race 90 degrees to the centerline of the
cage with the lands of the inner race (1) aligned with the windows
of cage (2).
- Insert the inner race into the cage.
- Hold the cage and the inner race 90 degrees
to the centerline of the outer race. Align the cage windows (3) with the lands
of the outer race (2).
Important: Ensure that the retaining ring side of the inner race faces the halfshaft
bar.
- Install the cage and the inner race into outer race.
- Place a brass drift against the CV joint
cage (1).
- Tap gently on the brass drift with a hammer in order to tilt the
cage (1).
- Install the first chrome alloy ball (2) when the CV joint
cage (1) tilts.
- Repeat this process to install all six of the balls.
- Pack the CV joint with half of the grease supplied in the service
kit.
- Install the new small retaining clamp
on the neck of the seal. Do not crimp.
- Clean the halfshaft bar. Use a wire brush to remove any rust in
the seal mounting area (grooves).
- Slide the CV joint seal onto the halfshaft bar. Expose the reference
mark (B) by sliding the CV joint seal up the halfshaft bar toward the
tripot end.
- Position the large seal retaining clamp
around the joint seal.
- Place the new retaining ring in the inner race.
- Slide the CV joint (2) on the halfshaft bar (1).
- Measure the distance between the reference
mark on the halfshaft bar (B) and the face of the CV joint inner race (1).
- Compare the mark with the measurement made before disassembly.
The distance measured after assembly must be within +-1 mm of the distance
measured before disassembly.
- Repeat the previous four steps if the current measurement does
not match the measurement made before disassembly.
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.
- Place the neck of the CV joint seal into the seal groove on the halfshaft
bar.
Important: Check the clamp position during the crimping operation in order to ensure
the clamp (1) is positioned correctly around the entire circumference.
- Crimp the small retaining clamp (1) by using J 35910
, a breaker bar, and a torque wrench.
Tighten
Tighten the seal retaining clamp to 136 N·m (100 lb ft).
- Check the gap dimension. Continue tightening until the gap dimension
is reached.
- Place the remaining grease from the service kit inside the seal.
- Measure approximately 17.5 mm
(11/16 in) up from the bottom edge of the CV outer joint assembly.
- Slide the large diameter of the seal with the large seal retaining
clamp in place over the outside of CV joint.
Important: The CV joint seal must not be dimpled, stretched or out of shape in
any way. If seal is not shaped correctly, equalize pressure in the seal and
shape the seal properly by hand.
- Locate the seal lip to the ridge of the CV outer joint assembly as measured
in the previous step.
- Crimp the seal retaining
clamp (1) with J 35910
, a breaker
bar (3) and a torque wrench (2).
Tighten
Tighten the seal retaining clamp to 176 N·m (130 lb ft).
- Check the gap dimension. Continue tightening until the correct
gap dimension is reached.
Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Out Joint and Seal
Tools Required
Important: Due to the helical splines on the halfshaft bar, disassembly and assembly
of the joints will be difficult. Follow the instructions provided.
- Remove the large seal retaining clamp from the CV joint with a side
cutter. Discard the large seal retaining clamp.
- Remove the small seal retaining clamp from the halfshaft bar with
a side cutter and discard.
- Separate the CV joint seal from the CV joint race (2) at
the large diameter.
- Slide the seal away from the joint along the halfshaft bar.
- Wipe the grease from the face of the CV joint inner race (1).
- Before removing the CV joint assembly from the halfshaft bar,
perform the following procedure:
6.1. | Choose a reference mark (B) on the halfshaft bar. |
6.2. | Measure the distance between the reference mark (B) and
the face of the CV joint inner race (1). Make a note of this measurement.
The measurement is (A). |
- Clamp the halfshaft (1) into a
vise.
- Attach the J 41398
to the threaded area of the outer race (2).
- Attach J 2619-01
onto the outer end of the J 41398
.
- Use the J 2619-01
to remove the
CV joint from the halfshaft bar.
- Remove J 2619-01
and J 41398
from the CV joint.
Important: Never reuse the retaining ring.
- Remove the retaining ring from the halfshaft bar. Discard the retaining
ring.
- Remove the CV joint seal (1) from the halfshaft bar.
- Place a brass drift against the CV joint
cage (1).
- Tap gently on the brass drift with a hammer in order to tilt the
cage (1).
- Remove the first chrome alloy ball (2) when the CV joint
cage (1) tilts.
- Tilt the CV joint cage (1) in the opposite direction to
remove the opposing chrome alloy ball (2).
- Repeat this process to remove all six of the balls.
- Pivot the CV joint cage (4) and
the inner race 90 degrees to the centerline of the outer race (1).
At the same time, align the cage windows with the lands of the outer race (2).
- Lift out the cage (4) and the inner race.
- Remove the inner race (1) from
the cage (2) by rotating the inner race (1) upward.
- Clean the inner and outer race assemblies, the CV joint cage and
the chrome alloy balls thoroughly with cleaning solvent. Remove all traces
of old grease and any contaminates.
- Dry all the parts.
- Check the CV joint assembly for unusual wear, cracks, or other
damage.
- Replace any damaged parts.
- Clean the halfshaft bar. Use a wire brush to remove any rust in
the seal mounting area (grooves).
Tools Required
J 35910 Seal Clamp Tool
- Put a light coat of grease from service
kit on the ball grooves of the inner race and the outer race.
- Hold the inner race 90 degrees to the centerline of the
cage with the lands of the inner race (1) aligned with the windows
of cage (2).
- Insert the inner race into the cage.
- Hold the cage and the inner race 90 degrees
to the centerline of the outer race. Align the cage windows (3) with the lands
of the outer race (2).
Important: Ensure that the retaining ring side of the inner race faces the outer
race.
- Install the cage and the inner race into outer race.
- Place a brass drift against the CV joint
cage (1).
- Tap gently on the brass drift with a hammer in order to tilt the
cage (1).
- Install the first chrome alloy ball (2) when the CV joint
cage (1) tilts.
- Repeat this process to install all six of the balls.
- Pack the CV joint with half of the grease supplied in the service
kit.
- Install the new small retaining clamp (2)
on the neck of the seal (3). Do not crimp.
- Clean the halfshaft bar (1). Use a wire brush to remove
any rust in the seal mounting area (grooves).
- Slide the CV joint seal (3) onto the halfshaft bar (1).
Expose the reference mark (4) by sliding the CV joint seal (3)
up the halfshaft bar (1) toward the tripot end.
- Position the large seal retaining clamp
around the joint seal.
- Place the new retaining ring onto the halfshaft bar.
- While supporting the tripot assembly, place the halfshaft assembly
onto the arbor press with the CV assembly under the press head.
- Lower the arbor press head onto the CV joint assembly until the
press cannot move any further. This ensures that the retaining ring engages
in the inner race. Do not exceed 4,000 lbs press load during assembly.
- Remove the halfshaft assembly from the arbor press.
- Measure the distance between the reference
mark on the halfshaft bar (B) and the face of the CV joint inner race (1).
- Compare the mark with the measurement made before disassembly.
The distance measured after assembly must be within +-1 mm (.039")
of the distance measured before disassembly.
- Repeat the previous four steps if the current measurement does
not match the measurement made before disassembly.
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.
- Place the neck of the CV joint seal into the seal groove on the halfshaft
bar.
Important: Check the clamp position during the crimping operation in order to ensure
the clamp (1) is positioned correctly around the entire circumference.
- Crimp the small retaining clamp (1) by using J 35910
, a breaker bar, and a torque wrench.
Tighten
Tighten the seal retaining clamp to 136 N·m (100 lb ft).
- Check the gap dimension. Continue tightening until the gap dimension
is reached.
- Place the remaining grease from the service kit inside the seal.
- Measure approximately 17.5 mm
(11/16 in) up from the bottom edge of the CV outer joint assembly.
- Slide the large diameter of the seal with the large seal retaining
clamp in place over the outside of CV joint.
Important: The CV joint seal must not be dimpled, stretched or out of shape in
any way. If seal is not shaped correctly, equalize pressure in the seal and
shape the seal properly by hand.
- Locate the seal lip to the ridge of the CV outer joint assembly as measured
in the previous step.
- Crimp seal retaining clamp (1)
with J 35910
, a breaker bar (3),
and a torque wrench (2).
Tighten
Tighten seal retaining clamp to 176 N·m (130 lb ft).
- Check the gap dimension. Continue tightening until the correct
gap dimension is reached.