Front Wheel Drive Shaft Outer Joint and Boot Replacement 3.6L LY7

Tools Required

J 42572 Drive Shaft Seal Clamp Pliers

1. Wrap a shop towel around the axle shaft.
2. Place the wheel drive shaft horizontally in a bench vise.
3. Remove the large seal retaining clamp from the outer joint seal.

Use a side cutter or other suitable tool and discard the clamp.

4. Remove the small seal retaining clamp from the joint seal.

Use a side cutter or other suitable tool and discard the clamp.

5. Separate the seal from the joint outer race at the large diameter end.
6. Position the seal behind the joint face.
7. Wipe the grease from the face of the joint inner race, cage, balls, etc.
8. Remove the outer joint from the axle shaft.

8.1.	Hold the joint housing.

8.2.	Position a wood block between the seal and the joint, along the joint face.

8.3.	Strike the wood block with a hammer to compress the axle shaft retaining clip.

8.4.	Continue to strike the wood block in order to remove the outer joint from the axle shaft.




9. Remove the axle shaft retaining ring from the axle shaft.



10. Remove the seal from the axle shaft.
11. Remove the wheel drive shaft from the vise.



12. Wrap a shop towel around the joint outer race splined shaft.
13. Place the outer race vertically in a bench vise.
14. Make a ball accessible for removal.

Tap gently on the joint cage, using a brass drift and a hammer, in order to drive a ball toward the bottom of its track. The opposing ball will be made accessible for removal.




15. Remove the exposed ball.

Use a small screwdriver to aid in removal if necessary.

16. Position the cage and inner race so they are level.



17. Repeat steps 14 through 16 in the removal sequence as shown until you remove all 6 balls.



18. Position the cage and the inner race 90 degrees to the centerline of the outer race.
19. Align the cage windows with the lands of the outer race.
20. Lift to remove the cage and the inner race from the outer race.



21. Position the cage and inner race so that the larger radius corners of the cage windows are up.
22. Rotate the inner race 90 degrees to the centerline of the cage.
23. Align the lands of the inner race with the windows of the cage.
24. Insert an inner race land into a cage window.
25. Pivot the inner race down and remove it from the cage.

Important: All traces of old grease and any contaminates must be removed.

26. Clean the following thoroughly with clean solvent:

•	The inner race

•	The outer race

•

The cage

•

The balls

•	The axle shaft exposed end.

27. Thoroughly air dry all the parts.

1. Position the cage so the larger radius corners of the cage windows are up.
2. Position the inner race 90 degrees to the centerline of the cage.
3. Begin to insert the inner race up through the bottom of the cage.
4. Align a land of the inner race to a window of the cage.
5. Insert the inner race land into the cage window.
6. Rotate the remainder of the inner race into the cage.
7. Rotate the inner race within the cage so that the grooved surface of the inner race is facing up.
8. Align the inner race ball tracks with the cage windows.



9. Wrap a shop towel around the joint outer race splined shaft.
10. Place the outer race vertically in a bench vise.
11. Position the cage and inner race 90 degrees to the centerline of the outer race.
12. Align 2 cage windows at 0 and 180 degrees.

Rotate the inner race and cage assembly in the vertical plane.

13. Align the two windows at 0 and 180 degrees with 2 of the outer race lands.
14. Insert the cage and inner race into the outer race.




Important: The larger radius corners of the cage windows should be positioned up and the grooved surface of the inner race should be visible.

15. Position the cage and inner race so they are level.
16. Align the cage windows and inner race ball tracks with the outer race ball tracks.
17. Position a cage window and inner race ball track for ball installation.

17.1.

Press down on the cage following one of the outer race ball tracks. The opposing cage window and inner race ball track will be accessible for ball installation.

17.2.

After installing the first ball, use a brass drift and a hammer to tap gently on the cage, in order to drive the cage and inner race down completely.

Important: No gap should exist between the ball and the inner race ball track.

18. Insert a ball through the cage window onto the inner race ball track.

Tap the ball lightly with a plastic tipped hammer.

19. Position the cage and inner race so they are level.




Important: The ball installation sequence must be followed as shown.

20. Repeat steps 17 through 19 in the installation sequence as shown until all 6 balls are installed.



21. Insert approximately 60 percent of the grease from the service kit into the outer joint.

21.1.

Spread the grease onto the ball tracks, the balls, the cage and the inner race.

21.2.

Spread the remainder of the grease into the bottom of the outer race.

22. Remove the outer joint from the bench vise.



23. Wrap a shop towel around the axle shaft.
24. Place the wheel drive shaft horizontally in a bench vise.
25. Install a new small seal retaining clamp onto the axle shaft.
26. Install the seal onto the axle shaft.



27. Install a new retaining ring to the axle shaft.



28. Position the outer joint horizontally.
29. Engage the inner race splines onto the axle shaft splines.
30. Compress the axle shaft retaining ring.

30.1.

Press the end of the retaining ring, using a flat bladed tool, into the axle shaft groove while firmly pressing the outer joint onto the axle shaft.

30.2.

Continue to work around the retaining ring until it is compressed.





Important: The axle shaft and inner race must be fully seated to each other.

31. Install the outer joint to the axle shaft.

31.1.

Position a wood block squarely over the end of the outer joint threaded shaft.

31.2.

Use a hammer to drive the outer joint onto the shaft.

31.3.

Continue to drive the outer joint until the outer joint seats fully onto the axle shaft.




32. Insert the remaining grease from the service kit into the seal.



33. Position the small seal retaining clamp (3) onto the neck of the seal (4).
34. Position the seal and small retaining clamp to the axle shaft (2) as shown.
35. Measure the distance (1) between the edge of the seal and the edge of the last axle shaft groove closing edge; adjust fit accordingly.

Specification
2.5 mm (0.10 in)





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.

Important: The seal retaining clamp must not be over-tightened or under-tightened.

36. Using the J 42572 , crimp the small seal retaining clamp.

Tighten
Tighten the small seal retaining clamp to 136 N·m (100 lb ft).

37. Measure the gap width (1) in order to ensure it is between 2 and 3 mm (0.079 and 0.118 in).



38. Position the large seal retaining clamp (2) onto the seal (3).
39. Position the seal and large retaining clamp to the joint outer race (4) as shown.
40. Measure the distance (1) between the edge of the seal and the edge of the joint outer race last groove closing edge; adjust fit accordingly.

Specification
0.8 mm (0.03 in)





Important: The seal must not be dimpled, stretched or otherwise deformed.

41. Inspect the seal for proper shape.

If the seal is not shaped correctly, equalize the pressure in the seal by lifting the seal edge slightly and shape the seal properly by hand.

42. Inspect the seal for damage.

If the seal has been cut or punctured during assembly, you must discard and replace the seal.

Important: The seal retaining clamp must not be over-tightened or under-tightened.

43. Using the J 42572 , crimp the large seal retaining clamp.

Tighten
Tighten the large seal retaining clamp to 136 N·m (100 lb ft).

44. Measure the gap width (1) in order to ensure it is between 2 and 3 mm (0.079 and 0.118 in).
45. Inspect the outer joint for smooth operation. This will also distribute the grease within the joint.

45.1.

Hold the wheel drive shaft vertically, with the outer joint at the bottom.

45.2.

Rotate the wheel drive shaft four or five times in a circular motion.

Front Wheel Drive Shaft Outer Joint and Boot Replacement 3.5L LX9

Tools Required

1. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the seal 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.

2. Use a hand grinder to cut through the swage ring in order to remove the swage ring.
3. Separate the halfshaft outboard seal from CV joint outer race (1) at large diameter.
4. Slide the seal (5) away from joint along halfshaft bar (4).
5. Wipe the grease from the face of the CV joint inner race (2).
6. Spread the ears on the race retaining ring (3) with J 8059 .
7. Remove the CV joint assembly (1) from the halfshaft bar (4).
8. Remove the halfshaft outboard seal (5) from the halfshaft bar (4).
9. Discard the old outboard seal.



10. Place a brass drift against the CV joint cage (1).
11. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
12. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts.
13. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2).
14. Repeat this process to remove all 6 of the balls.



15. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (2). At the same time, align the cage windows  (3) with the lands of the outer race.
16. Lift out the cage (4) and the inner race.



17. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward.
18. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.

•	The inner and outer race assemblies

•	The CV joint cage

•	The chrome alloy balls

19. Dry all the parts.
20. Check the CV joint assembly for the following items:

•	Unusual wear

•

Cracks

•

Damage

21. Replace any damaged parts.
22. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).

1. Install the new swage ring or eared clamp (2) on the neck of the outboard seal (1). Do not swage or crimp.
2. Slide the outboard seal (1) onto the halfshaft bar and position the neck of the outboard seal (1) in the seal groove on the halfshaft bar. The largest groove below the sight groove on the halfshaft bar is the seal groove (3).




Important: For eared clamp installation, proceed to step 6.

3. For swage ring installation use J 41048 in the following way:

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

3.2.	Align the swage ring.

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

Notice: Refer to Fastener Notice in the Preface section.

Important: Align the following items during this procedure:    •  The outboard seal (1)    •  The halfshaft bar    •  The swage ring

3.4.	Insert the bolts (2) and tighten by hand until snug.

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




4. Loosen the bolts and separate the dies.
5. Check swaged ring (2) for any lip deformities. If present, place the ring (2) back into the J 41048 making sure the ring covers the whole swaging area. If necessary, re-swage the ring.




Important: Place a towel in the vise before inserting the halfshaft.

6. For eared clamp installation, mount the halfshaft into a vise.
7. Install the new eared clamp (2) on the neck of the seal. Do not crimp.
8. Slide the seal (1) onto the halfshaft bar and position the neck of the seal in the seal groove (3) on the bar.



9. Crimp the eared clamp (1) using the J 35910 , a breaker bar, and a torque wrench.

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

10. Check the gap dimension, continue tightening until the gap dimension is reached.



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



13. Hold the cage and the inner race 90 degrees to centerline of the outer race (1) and align the cage windows (3) with the lands of the outer race.

Important: Be sure that the retaining ring side of the inner race faces the halfshaft bar.

14. Place the cage and the inner race into the outer race.
15. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball.
16. Repeat this process until all 6 balls are in place.
17. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease.



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




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

19. 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.



20. Crimp the seal retaining clamp (1) using J 35910 .

Tighten
Crimp the clamp (1) to 174 N·m (130 lb ft).

21. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Dimension a= 1.9 mm (5/64 in).