Wheel Drive Shaft Inner Joint and Boot Replacement FE7

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.

1. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. Discard the retaining clamp.
2. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp.
3. Separate the inboard seal from the trilobal tripot bushing (3) at the large diameter.
4. Slide the seal away from the joint along the halfshaft bar.



5. Remove the housing (1) from the tripot joint spider and the halfshaft bar (2).



6. Spread the spacer ring (1) using J 8059 (or equivalent).



7. Remove the spacer ring (1), spider assembly (2), spacer ring (3) (if equipped) using J 8059 , and tripot boot (4). Discard the boot and rings.
8. Clean the halfshaft bar (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves).
9. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit.

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

1. Mount the halfshaft into a vise.
2. Place the new small eared clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the eared clamp (2) onto the halfshaft bar.
3. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.



4. Crimp the eared clamp (6) using J 35910 , a torque wrench (8), and a breaker bar (9).



5. If equipped, install the spacer ring (2) into the groove of the halfshaft bar using J 8059 .



6. Slide the tripot joint spider assembly (4) as far as it will go on the halfshaft bar.
7. Install the spacer ring (2) into the groove of the halfshaft bar J 8059 .



8. Place approximately half of the grease from the service kit in the halfshaft inboard seal. 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 (1).
10. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal.
11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.



12. Slide the large diameter of the halfshaft inboard seal (2), with larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.
13. Position the joint assembly at the proper vehicle dimension, a = 106 mm (4.00 in).
14. Carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the trilobal tripot bushing in order to equalize the pressure. Remove the tool.



15. Align the following items while latching:

•	The halfshaft inboard seal

•	The tripot housing (2)

•	The large seal retaining clamp (3)

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.

16. Check the gap dimension (a) on the clamp ear. If the gap dimension is larger than shown, continue tightening until the gap dimension of 2.6 mm (0.102 in) is reached.
17. Fully stroke the joint several times to disperse the grease.

Wheel Drive Shaft Inner Joint and Boot Replacement FE1/FE3

Tools Required

Important: With removal of the halfshaft for any reason, the transmission sealing surface (the tripot male/female shank of the halfshaft) 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 halfshaft 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 halfshaft inboard boot from the trilobal tripot bushing (3) at the large diameter.
5. Slide the boot (4) away from the joint along the halfshaft bar.
6. Remove the housing (1) from the tripot joint spider (2) and the halfshaft bar.
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 halfshaft bar.
9. Slide tripot joint spider assembly (2) off of the halfshaft bar.
10. Remove and discard the second spacer ring (3) from the halfshaft bar.
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 halfshaft bar.
2. Position the small end of the joint boot (1) into the joint boot groove (3) on the halfshaft bar.



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

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

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

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

3.4.	Before proceeding, ensure there are no pinch points on the halfshaft inboard boot. This could cause damage to the halfshaft 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 halfshaft inboard boot (1)

•	The halfshaft bar boot grooves

•	The swage ring (2)

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. Install the spacer ring (2) on the halfshaft bar (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 halfshaft bar (4).
7. Install the halfshaft bar retaining ring  (2) in the groove of the halfshaft bar  (4).



8. Place approximately half of the grease from the service kit in the halfshaft inboard boot. Use the remainder of the grease to repack the housing.
9. Install the trilobal tripot bushing (3) to housing.

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

10. Position the larger new boot retaining clamp (2) on the halfshaft inboard boot.
11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.



12. Slide the large diameter of the halfshaft 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.