Wheel Drive Shaft Outer Joint and Boot Replacement FE1/FE3

Special Tools

1. Remove the large boot retaining clamp from the CV joint with a side cutter. Discard the boot retaining clamp.
2. Remove the small boot retaining clamp from the halfshaft bar with a side cutter. Discard the boot retaining clamp.
3. Separate the outboard boot (5) from CV joint outer race (1) at the large diameter and slide the boot (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 boot (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 6 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 races

•	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 boot (1). Slide the boot (1) and the swage ring (2) onto the halfshaft bar.
2. Position the small end of the boot (1) into the boot 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 boot 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 boot. This could cause damage to the boot.

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 halfshaft outboard 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. 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 6 balls are in place.
11. Place approximately half the grease from the service kit inside the outboard boot 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 boot (1) must not be dimpled, stretched or out of shape in any way. If the boot (1) is not shaped correctly, equalize the pressure in the boot (1) and shape the boot (1) properly by hand.

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



14. Crimp the boot 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 clamp gap dimension on the clamp ear. If the gap dimension is larger than shown, continue tightening until gap dimension is reached (dimension a = 1.9 mm).

Wheel Drive Shaft Outer Joint and Boot Replacement FE7

Special Tools

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

Caution: 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. Remove the small eared clamp with a side cutter. Discard the eared clamp.
4. Separate the halfshaft outboard seal from CV joint outer race (1) at large diameter.
5. Slide the seal (5) away from joint along halfshaft bar (4).
6. Wipe the grease from the face of the CV joint inner race (2).
7. Spread the ears on the race retaining ring (3) with J 8059 .
8. Remove the CV joint assembly (1) from the halfshaft bar (4).
9. Remove the halfshaft outboard seal (5) from the halfshaft bar (4).
10. Discard the old outboard seal.



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



16. 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.
17. Lift out the cage (4) and the inner race.



18. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward.
19. 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

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

•	Unusual wear

•

Cracks

•

Damage

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

Note: For eared clamp, place a towel in the vise before inserting the halfshaft.

1. For eared clamp installation, mount the halfshaft into a vise.
2. Install the new swage ring or eared clamp (2) on the neck of the outboard seal (1). Do not swage or crimp.
3. 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).




Note: For eared clamp installation, proceed to step 7.

4. For swage ring installation use DT-48267 in the following way:

4.1.	Position the outboard end of the halfshaft assembly (1) in DT-48267 .

4.2.	Align the swage ring.

4.3.	Place the top half of DT-48267 on the lower half of DT-48267 .

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

4.4.	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.




5. Loosen the bolts and separate the dies.
6. Check swaged ring (2) for any lip deformities. If present, place the ring (2) back into the DT-48267 making sure the ring covers the whole swaging area. If necessary, re-swage the ring.

Caution: Refer to Fastener Caution in the Preface section.




7. 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).

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



9. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race.
10. 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.



11. 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.

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

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



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




Note: 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.

17. 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.



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

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

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