Wheel Drive Shaft Inner Joint and Boot Replacement Free Motion

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. Perform the following steps if the transaxle stub shaft has disengaged into the female tripot housing on removal from transaxle.

Important: Never reuse the snap ring.

2. Remove the snap ring from the stub shaft.
3. Discard the snap ring.



4. Connect the J 38868 to the snap ring groove on the stub shaft and connect an J 6125-1B to the J 38868 .
5. Use the J 6125-1B to remove the shaft from the tripot housing.
6. Install new snap rings onto the stub shaft.
7. Refer to the transaxle unit repair for the proper installation of the stub shaft into the transaxle.




Important: Do not cut through the halfshaft inboard seal and damage sealing surface of the outer housing and the trilobal tripot bushing.

8. Remove the small seal retaining clamp from the halfshaft bar with a side cutter.
9. Discard the small seal retaining clamp.
10. Remove the large seal retaining clamp from the tripot joint with side cutter.
11. Discard the large seal retaining clamp.
12. Separate the tripot seal from the trilobal tripot bushing at the large diameter.
13. Slide the seal away from the joint along the halfshaft bar.
14. Remove the housing from the tripot joint spider and the halfshaft bar.
15. Spread spacer ring (2) with J 8059 .
16. Slide the spacer ring (2) and tripot joint spider back on halfshaft bar (1).
17. Remove the halfshaft bar retaining ring from the groove on the halfshaft bar (1).



18. Slide tripot joint spider assembly off of the halfshaft bar (1).
19. Clean the following items with cleaning solvent:

•	The tripot balls

•	The needle rollers

•	The housing

20. Remove all traces of old grease and any contaminates. Dry all the parts.
21. Remove the trilobal tripot bushing from the housing and discard.
22. Remove the spacer ring (2) and the seal (3) from the halfshaft bar.
23. Inspect the following parts for damage or wear:

•	The halfshaft inboard seal (3)

•	The tripot joint spider assembly (1)

•	The housing

•	The tripot balls

•	The needle rollers

1. Install the new small seal retaining clamp (2) on the neck of the tripot seal (1).
2. Do not crimp the small seal retaining clamp.
3. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).
4. Slide the tripot seal (7) onto 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.

5. Position the neck of the tripot seal in the seal groove (3) on the halfshaft bar.
6. Crimp the seal retaining clamp (6) using J 35910 , a breaker bar (9) and a torque wrench (8).

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

7. Check the gap dimension. Continue tightening until the gap dimension is reached.



8. Install the spacer ring (2) on the halfshaft bar (1) and beyond the second groove.



9. Slide the tripot joint spider assembly (3) toward the spacer ring as far as it will go on the halfshaft bar.

Important: Ensure that the counterbored face of the tripot joint spider (4) faces end of the halfshaft bar.

10. Install the halfshaft bar retaining ring (2) in the groove of the halfshaft bar using J 8059 .
11. Slide the tripot joint spider assembly (3) towards the end of the halfshaft bar.
12. Reseat the spacer ring in the groove on the halfshaft bar.
13. 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. Ensure the bushing is flush with the face of the housing.
14. Install the trilobal tripot bushing to housing.



15. Position the larger new clamp (3) on the halfshaft inboard seal (2).
16. Slide the housing (4) over the tripot joint spider assembly on the halfshaft bar (1).
17. Slide the large diameter of the halfshaft inboard seal (2), with the larger clamp (3) in place, over the outside of the trilobal tripot bushing.
18. Locate the lip of the seal in the groove.
19. Position the joint assembly at the proper vehicle dimension.




Important: The halfshaft inboard seal (3) must not be dimpled, stretched out or out of shape in any way. If the halfshaft inboard seal (3) is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between the large seal opening and the trilobal tripot bushing to equalize the pressure. Shape the halfshaft inboard seal (3) properly by hand. Remove the thin, flat, blunt tool.

Important: Align the following items while latching:

•	The halfshaft inboard seal (3)

•	The housing (1)

•	The large clamp (2)

20. Latch the seal retaining clamp (2) using J 35566 .

Wheel Drive Shaft Inner Joint and Boot Replacement Trilobal

Tools Required

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. Remove the small seal retaining clamp from the halfshaft bar (3) with a side cutter. Discard the small seal retaining clamp.
2. Remove the large seal retaining clamp from the inboard joint with a side cutter. Discard the large seal retaining clamp.
3. Separate the inboard seal  from the trilobal tripot bushing (2) at large diameter.
4. Slide seal away from joint along halfshaft bar (3).



5. Before removing the tripot spider assembly (3) from the halfshaft bar, perform the following procedure:

Important: Never reuse the spacer ring (2).

6. Remove the spacer ring (2) from the end of the halfshaft bar using J 8039-A .



7. Place a brass drift on the area of the tripot spider (1) next to the halfshaft bar (3).
8. Tap on the brass drift with the hammer.

Important: Handle the tripot spider assembly (1) with care.

9. Remove the tripot spider assembly (1) from the halfshaft bar (3).
10. Remove the spacer ring  (2) from the shoulderof the halfshaft bar  (3) using J 8039-A
11. Remove and discard the trilobal tripot bushing from the housing.
12. Clean the following items thoroughly with cleaning solvent. Removing all traces of old grease and any contaminates.

•	The tripot balls

•	The needle rollers

•	The housing

13. Dry all the parts.
14. Remove and discard the seal from the halfshaft bar.
15. Inspect the following parts for damage or wear:

•	The spider assembly (3)

•	The housing

•	The tripot balls

•	The needle rollers

1. Install the new small seal retaining clamp on the neck of the seal.
2. Do not crimp the small seal retaining clamp.
3. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).
4. Slide the tripot seal and clamp onto the halfshaft bar, passing the seal grooves of the halfshaft bar toward the CV end of the halfshaft bar.

Important: Ensure that the spacer ring (1) is next to the shoulder of the halfshaft bar before installing the tripot spider (3).

5. Place the new spacer ring (1) next to the shoulder on the halfshaft bar.
6. Place the tripot spider assembly (3) onto the halfshaft bar.



7. Place the halfshaft assembly onto the arbor press.

•	The tripot spider assembly must be on the press plate.

•	The CV joint assembly must be under the press head.

8. Lower the arbor press head onto the CV joint assembly until the tripot spider is next to the spacer ring. Do not exceed 4,000 lbs (1,779 N) press load during assembly.
9. Remove the halfshaft assembly from the arbor press.



10. Place the new spacer ring (2) on the halfshaft bar groove at the end of the halfshaft bar.



11. Slide the tripot seal (7) to the corresponding groove on the halfshaft bar.
12. Crimp the small seal retaining clamp (6) using J 35910 , a torque wrench (8), and a breaker bar (9).
13. Place approximately ¼ of the grease from the service kit in seal. Use the remainder to repack the housing.



14. Install the new trilobal tripot bushing (2) to housing (1). Ensure the bushing (2) is flush with the face of the housing (1).
15. Slide the housing (1) over the spider assembly on the halfshaft bar (3).

Important: The end of the inboard seal (4) must be next to the seal stop on the trilobal tripot bushing (2).

16. Position the large seal retaining clamp around the inboard seal (4).
17. Engage the inboard seal (4).




Important: The halfshaft inboard seal (2) must not be dimpled, stretched out or out of shape in any way. If the halfshaft inboard seal (2) is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between the large seal opening and the trilobal tripot bushing to equalize the pressure. Shape the halfshaft inboard seal (2) properly by hand. Remove the thin, flat, blunt tool.

18. Position joint assembly at the proper vehicle dimension.

•	For vehicles with 2.2L engines and automatic transmissions, dimension a=90  mm  (3.5 in).

•	For all other vehicles, dimension a=115  mm  (4.5 in).




19. Align the following items while latching:

•	The halfshaft inboard seal (3)

•	The housing (1)

•	The large clamp (2)

20. Latch the seal retaining clamp (2) using J 35566 if the clamp is earless or crimp the seal retaining clamp  (2) using J 35910 if the joint uses an eared clamp.
21. Stroke the joint to full extension and compresssion several times to distribute the grease.