SMU - Revised Wheel Drive Shaft Inner Joint and Seal Replacement

This bulletin is being issued to revise the Wheel Drive Shaft Inner Joint and Seal Replacement procedure in the Rear Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information.

The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page.

Tools Required

Disassembly Procedure

Important: Use caution when using the hand grinder by the tripot housing (1).

1. Use a hand grinder in order to cut through the swage ring (2).
2. Remove the tripot housing (1) from the halfshaft.
3. Wipe the grease off of the housing (1).
4. Thoroughly degrease the tripot housing (1).
5. Allow the tripot housing (1) to dry prior to assembly.



6. Using side cutters, remove the small boot retaining clamp.
7. Remove the following items from the halfshaft bar:

7.1.	The spacer ring (1)

7.2.	The tripot spider assembly (2)

7.3.	The tripot boot (3)

8. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal 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 service kit.

Assembly Procedure

1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint seal (1) and small seal clamp (2) onto the halfshaft bar.
2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.




Notice: Refer to Fastener Notice in Cautions and Notices.

3. Secure the small seal clamp (1) with J 35910 (or equivalent), a breaker bar, and a torque wrench.

Tighten
Tighten the small seal clamp (1) to 136 N·m (100 lb ft).

4. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.




Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated.

5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following convolutions:

•	2-5 for the 1500 model (except 1500HD)

•	2-4 for the 1500HD, 2500, 3500, and HUMMER H2 models.




6. Install the tripot spider assembly (3) onto the halfshaft bar (2).
7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2).



8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.



9. Reassemble the tripot housing and the tripot seal using the following procedure:

9.1.	Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape.

9.2.	Slide the distorted swage ring (2) over the large diameter of the seal.

9.3.	Place the tripot housing over the spider assembly.

9.4.	Install the seal onto the tripot housing.

9.5.	Align the tripot seal (1), with the swage ring (2) in place, over the flat area on the tripot housing (3).




10. For the 1500 models (except 1500HD), assemble the bolts and the support plate to the base of the J-36652-01 and secure the base in a vise.
11. For the 1500HD, 2500, 3500, and HUMMER H2 models, assemble the bolts and the support plate to the base of the J 36652-98 and secure the base in a vise.



12. Inspect the inboard stroke position.

•	Use measurement A for the 1500 models (except 1500HD).

•	Use measurement B for the 1500HD, 2500, 3500, and HUMMER H2 models.




13. Position the inboard end (tripot end) of the halfshaft assembly into the base of the J-36652-01 for the 1500 models (except 1500HD) or J 36652-98 for the 1500HD, 2500, 3500 and HUMMER H2 models.
14. Install the top half of the J-36652-01 for the 1500 models (except 1500HD) or J 36652-98 for the 1500HD, 2500, 3500 and HUMMER H2 models.
15. Align the swage ring (2) and the swage ring clamp.
16. Insert the bolts.

Tighten
Hand tighten the bolts until the bolts are snug.

Important: Align the following during this procedure:

•	The tripot boot (3)

•	The tripot housing (1)

•	The swage ring (2)

Tighten
Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half .

17. Loosen the bolts and remove the halfshaft assembly from the tool.



18. Remove the convolute retainer tool from the boot.