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.)).