Special Tools

1. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the seal retaining clamp.
2. Remove the small seal retaining clamp from the halfshaft bar with a side cutter. Discard the seal retaining clamp.
3. Separate the outboard seal (5) from CV joint outer race (1) at the large diameter and slide the seal (5) away from the CV joint along the bar (4).
4. Wipe the grease from the face of the CV joint inner race (2).
5. Spread the ears on the race retaining ring (3) using J 8059 and remove the CV joint assembly from the bar (4).
6. Remove the seal (5) from the bar (4).



7. Use a brass drift and a hammer to gently tap on the CV joint cage (1) until it is tilted enough to remove the first chrome alloy ball (2).
8. Tilt cage in the opposite direction to remove the opposing ball (2).
9. Repeat this process until all balls are removed.



10. Position the CV joint cage (4) and the CV joint inner race 90 degrees to the centerline of the CV joint outer race (1) and align the CV joint cage windows (3) with the lands of the CV joint outer race (1).
11. Remove the CV joint cage (4) and the CV joint inner race from the CV joint outer race (1).



12. Rotate the CV joint inner race 90 degrees to the centerline of the CV joint cage with the lands of the CV joint inner race (1) aligned with the windows of the CV joint cage (2).
13. Pivot the inner race into the cage window (2) and remove the inner race (1).
14. Clean the following items thoroughly with cleaning solvent:

•	The inner and outer race assemblies

•	The CV joint cage

•

The balls

15. Remove all traces of old grease and any contaminates.
16. Dry all the parts.

1. Place the new swage ring (2) onto the small end of the joint seal (1). Slide the seal (1) and the swage ring (2) onto the halfshaft bar.
2. Position the small end of the seal (1) into the seal groove (3) on the halfshaft bar.



3. Mount J 41048 in a vise and proceed as follows:

3.1.	Position the outboard end (1) of the halfshaft assembly in tool J 41048 .

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

3.3.	Place the top half of the J 41048 on the lower half of the J 41048 .

3.4.	Before proceeding, ensure there are no pinch points on the seal. This could cause damage to the seal.

3.5.	Insert the bolts (2).

3.6.	Tighten the bolts by hand until snug.

Caution: Refer to Fastener Caution in the Preface section.




4. Align the following items:

•	The seal (1)

•	The swage ring (2)

•	The halfshaft bar

Tighten
Tighten each bolt of J 41048 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.




5. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race (1).
6. Hold inner race 90 degrees to the centerline of the cage (4) with the lands of the inner race aligned with the windows of the cage and insert the inner race into the cage.
7. Hold the cage and the inner race 90 degrees to the centerline of the outer race (1) and align the cage windows (3) with the lands of the outer race (2).

Note: Ensure that the retaining ring side of the inner race faces the halfshaft bar.

8. Place the cage (4) and the inner race into the outer race (1).
9. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball.
10. Repeat this process until all balls are in place.
11. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease.



12. Push the CV joint (2) onto the halfshaft bar (1) until the retaining ring is seated in the groove on the bar.




Note: The outboard seal (1) must not be dimpled, stretched or out of shape in any way. If the seal (1) is not shaped correctly, equalize the pressure in the seal (1) and shape the seal (1) properly by hand.

13. Slide large diameter of the outboard seal (1) with the large seal retaining clamp (2) in place over the outside of the CV joint outer race (3) and locate the seal lip in the groove on the CV joint outer race (3).



14. Crimp the seal retaining clamp (1) using J 35910 , a breaker bar (3), and a torque wrench (2)

Tighten
Tighten to 176 N·m (130 lb ft).

15. Check the gap dimension on the clamp ear. If the gap dimension is larger than shown, continue tightening until gap dimension of 2.60 mm (0.102 in) is reached