Wheel Drive Shaft Outer Joint and Boot Replacement Drive Shaft Bar Diameter 24 MM

Tools Required

Important: Due to the helical splines on the halfshaft bar, disassembly and assembly of the joints will be difficult. Follow the instructions provided.

1. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the large seal retaining clamp.
2. Remove the small seal retaining clamp from the halfshaft bar with a side cutter and discard.
3. Separate the CV joint seal from the CV joint race (2) at the large diameter.
4. Slide the seal away from the joint along the halfshaft bar.
5. Wipe the grease from the face of the CV joint inner race (1).
6. Before removing the CV joint assembly from the half shaft bar, perform the following procedure:

6.1.	Choose a reference mark (B) on the halfshaft bar.

6.2.	Measure the distance between the reference mark (B) and the face of the CV joint inner race (1). Make a note of this measurement. The measurement is (A).

6.3.	Mark the inboard side (toward the center of the half shaft bar) of the CV joint inner race (1) as a reference.

6.4.	Inspect the CV joint inner race/halfshaft bar interface for the presence of a retaining ring. If present, remove the retaining ring using J 8039-A




7. Clamp the halfshaft (1) into a vise.



8. Attach the J 41398 to the threaded area of the outer race (2).



9. Attach J 2619-01 onto the outer end of the J 41398 .
10. Use the J 2619-01 to remove the CV joint from the halfshaft bar.
11. Remove J 2619-01 andJ 41398 from the CV joint.

Important: Never reuse the retaining ring.

12. Remove the retaining ring from the halfshaft bar. Discard the retaining ring.
13. Remove the CV joint seal (1) from the halfshaft bar.



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



19. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (1). At the same time, align the cage windows with the lands of the outer race (2).
20. Lift out the cage (4) and the inner race.



21. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward.
22. Clean the inner and outer race assemblies, the CV joint cage and the chrome alloy balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.
23. Dry all the parts.
24. Check the CV joint assembly for unusual wear, cracks, or other damage.
25. Replace any damaged parts.
26. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).

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



4. Hold the cage and the inner race 90 degrees to the centerline of the outer race. Align the cage windows (3) with the lands of the outer race (2).

Important: Ensure that the inner race is oriented the same as prior to disassembly. Use the reference mark placed earlier.

5. Install the cage and the inner race into outer race.



6. Place a brass drift against the CV joint cage (1).
7. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
8. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts.
9. Repeat this process to install all six of the balls.
10. Pack the CV joint with half of the grease supplied in the service kit.



11. Install the new small retaining clamp (2) on the neck of the seal (3). Do not crimp.
12. Clean the halfshaft bar (1). Use a wire brush to remove any rust in the seal mounting area (grooves).
13. Slide the CV joint seal (3) onto the halfshaft bar (1). Expose the reference mark (4) by sliding the CV joint seal (3) up the halfshaft bar (1) toward the tripot end.



14. Position the large seal retaining clamp around the joint seal.
15. Place the new retaining ring onto the halfshaft bar.
16. While supporting the tripot assembly, place the halfshaft assembly onto the arbor press with the CV assembly under the press head.
17. Lower the arbor press head onto the CV joint assembly until the press cannot move any further. This ensures that the retaining ring engages in the inner race. Do not exceed 1779 N (4,000  lbs) press load during assembly.
18. Remove the halfshaft assembly from the arbor press.



19. Measure the distance between the reference mark on the halfshaft bar (B) and the face of the CV joint inner race (1).
20. Compare the mark with the measurement made before disassembly.
21. Repeat the previous four steps if the current measurement does not match the measurement made before disassembly.



22. Place the neck of the CV joint seal into the seal groove on the halfshaft bar.

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: Check the clamp position during the crimping operation in order to ensure the clamp (1) is positioned correctly around the entire circumference.

23. Crimp the small retaining clamp (1) by using J 35910 , a breaker bar, and a torque wrench.

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

24. Check the gap dimension. Continue tightening until the gap dimension is reached.
25. Place the remaining grease from the service kit inside the seal.



26. Measure approximately 17.5 mm (11/16  in) up from the bottom edge of the CV outer joint assembly.
27. Slide the large diameter of the seal with the large seal retaining clamp in place over the outside of CV joint.

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

28. Locate the seal lip to the ridge of the CV outer joint assembly as measured in the previous step.



29. Crimp seal retaining clamp (1) withJ 35910 , a breaker bar (3), and a torque wrench (2).

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

30. Check the gap dimension. Continue tightening until the correct gap dimension is reached. Dimension a=3.9 mm (0.15 in).

Wheel Drive Shaft Outer Joint and Boot Replacement Drive Shaft Bar Diameter 27 MM

Tools Required

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 (4) with a side cutter. Discard the seal retaining clamp.
3. Separate the seal (5) from the CV joint outer race (1) at large diameter and slide the seal (5) away from joint along 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 the J 8059 and remove the CV joint assembly (1) from the bar (4).
6. Remove the seal (5) from the bar (4).



7. Use a brass drift and a hammer in order to gently tap on the CV joint cage (1) until the cage is tilted enough to remove the first chrome alloy ball (2).
8. Tilt the cage in the opposite direction in order to remove the opposing ball.
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).

Align the CV joint cage windows (3) with the lands of the CV joint outer race (2).

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 and remove the inner race.
14. Clean the inner and outer race assemblies, the CV joint cage and the balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.
15. Dry all of the parts.

1. Install the new seal retaining clamp (2) on the neck of the seal. Do not crimp.
2. Slide the seal (1) onto the halfshaft bar and position the neck of the seal in the seal groove (3) on the bar.




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.

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

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

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



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

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

8. Place the cage and the inner race into the outer race.
9. Insert the first chrome ball then tilt the cage in the opposite direction in order 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 seal and pack the CV joint with the remaining grease.



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




Important: Ensure that the seal (1) is not dimpled, stretched, or out of shape. If the seal is not shaped correctly, equalize the pressure in the seal and shape the seal properly by hand.

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



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

Tighten
Tighten the seal retaining clamp to 176 N·m (130 lb ft).

16. Check the gap dimension, continue tightening until the gap dimension is reached (dimension a=1.90mm (1/16 in.)).