Wheel Drive Shaft Inner Joint and Boot Replacement Delphi

Tools Required

Important: With removal of the wheel driveshaft for any reason, the transmission sealing surface (the tripot male/female shank of the wheel driveshaft) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent in a rotation motion. Do not clean with an oscillating motion. Transmission fluid may be used to clean off any remaining debris. The surface should be wiped dry and the wheel driveshaft reinstalled free of any buildup.

1. Use a hand grinder in order to cut through the swage ring. Do not damage the tripot housing (1).
2. Remove the large boot retaining clamp from the tripot joint with side cutter.
3. Dispose of the large boot retaining clamp.

Notice: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.

4. Separate the wheel driveshaft inboard boot from the trilobal tripot bushing (3) at the large diameter.
5. Slide the boot (4) away from the joint along the shaft.
6. Remove the housing (1) from the tripot joint spider (2) and the shaft.
7. Remove and discard the trilobal tripot bushing (3) from the housing (1).



8. Remove and discard the lower spacer ring (1) from the groove (5) on the shaft.
9. Slide tripot joint spider assembly (2) off of the shaft.
10. If present, remove and discard the second spacer ring (3) from the shaft.
11. Clean the following items with cleaning solvent:

•	The tripot balls

•	The needle rollers

•	The housing

12. Remove all traces of old grease and any contaminates. Dry all parts.



13. Inspect the following parts for damage or wear:

•	The tripot joint spider assembly (2)

•	The housing (1)

•	The needle rollers

1. Place the new small boot clamp (2) onto the small end of the joint boot (1). Slide the joint boot (1) and the small boot clamp (2) onto the shaft.
2. Position the small end of the joint boot (1) into the joint boot groove (3) on the shaft.



3. Mount DT-47732 in a vise and proceed as follows:

3.1.	Position the inboard end (1) of the wheel driveshaft assembly in tool DT-47732 .

3.2.	Align the top of boot neck on the bottom die using the indicator.

3.3.	Place the top half of tool DT-47732 on the lower half of tool.

3.4.	Before proceeding, ensure there are no pinch points on the wheel driveshaft inboard boot. This could cause damage to the inboard boot.

3.5.	Insert the bolts (2).

3.6.	Tighten the bolts by hand until snug.

Notice: Refer to Fastener Notice in the Preface section.




4. Align the following items:

•	The inboard boot (1)

•	The shaft boot grooves

•	The swage ring (2)

Tighten
Tighten each bolt of DT-47732 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.




5. If equipped, install the spacer ring (2) on the shaft (1) in groove using J 8059 .



6. Slide the tripot joint spider assembly (3) toward the spacer ring (1) as far as it will go on the shaft (4).
7. Install the shaft retaining ring (2) in the groove of the shaft (4).



8. Place approximately half of the grease from the service kit in the shaft inboard boot. Use the remainder of the grease to repack the housing.

Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).

9. Install the trilobal tripot bushing (3) to housing.
10. Position the larger new boot retaining clamp (2) on the shaft inboard boot.
11. Slide the housing (1) over the tripot joint spider assembly on the shaft.



12. Slide the large diameter of the inboard boot (2), with the larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove.
13. Position the joint assembly at dimension a = 107 mm (4.21 in).
14. Carefully insert a thin flat blunt tool (no sharp edges) between the large boot opening and the trilobal tripot bushing in order to equalize the pressure. Remove the tool.



15. Align the following items while latching:

•	The seal  (3)

•	The tripot housing (2)

•	The large seal retaining clamp

Tighten
Crimp the seal retaining clamp with J 35910 to 176 N·m (130 lb ft). Add the breaker bar (5) and the torque wrench (4) to J 35910 if necessary.

•	Verify dimension a = 2.15 mm (0.085 in).

16. Fully stroke the joint several times to disperse the grease.

Wheel Drive Shaft Inner Joint and Boot Replacement GKN

Tools Required

J 35910 Drive Axle Seal Clamp Pliers

1. Position wheel drive shaft bar in a soft jawed vise and clamp securely.
2. Using side cutters, remove and discard the small seal clamp.



3. Remove large seal retaining clamp using a flat-bladed tool and discard the clamp.



4. Separate the seal from the tripot housing at the large diameter and slide the seal away from the joint along the axle shaft.
5. Wipe the excess grease from the face of the tripot spider and the inside of the tripot housing.
6. Remove the tripot housing from the spider and shaft.



7. Remove the retaining ring from the groove on the wheel drive shaft bar and remove the spider assembly.
8. Remove the seal from the wheel drive shaft bar.
9. Thoroughly clean all parts with a suitable solvent, removing all traces of grease and contaminants.
10. Dry all parts with compressed air.
11. Inspect the tripot joint components for unusual wear, cracks, and other damage. Replace any damaged components.

1. Install the small seal clamp to the seal. Do not crimp the clamp.
2. Slide the inner seal onto the wheel drive shaft bar and locate the lip of the seal groove on the wheel drive shaft bar.

Important: Ensure the seal clamp is positioned correctly in the seal groove.

3. Using the J 35910 , crimp the small seal clamp.
4. Measure the clamp gap width.

Specification
Clamp gap width should not exceed 2.15 mm (0.85 in).




5. Install the tripot spider assembly to the wheel drive shaft bar, until seated against shoulder.
6. Install the retaining ring in the groove of the wheel drive shaft bar with suitable pliers.
7. Place approximately half of the grease in the kit to the seal and place the remainder in the tripot housing.



8. Install the large clamp over the large diameter of the seal.
9. Install the tripot housing to the tripot spider assembly on the wheel drive shaft bar.
10. Slide the large diameter of the seal over the outside of the tripot housing and position the lip of the seal in the housing groove.



11. Place the large seal retaining clamp around the seal and close using J 35910 .
12. Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.

Specification
Dimension equals 1.9 mm (5/64 in).

13. Rotate the housing in a circular motion to distribute the grease in the tripot joint.