Wheel Drive Shaft Inner Joint and Boot Replacement W/O Z06, Z51

Special Tools

Note: If the inner joint is found to have excessive wear or damaged inner components, replace the wheel drive shaft as an assembly. The inner joint and it's inner components are not serviced.

1. Remove the wheel drive shaft from the vehicle. Refer to Wheel Drive Shaft Replacement.



2. Wrap a shop towel around the axle shaft.
3. Install the wheel drive shaft horizontally in a bench vise.
4. Using the J 46588 , remove the large seal retaining clamp from the CV joint seal.
5. Using a side cutter, remove and discard the small boot clamp.
6. Remove the boot from the outer joint housing and position the boot down the wheel drive shaft..

Note: Position the wheel drive shaft so that the inner joint is facing up and the outer joint is facing down.

7. Install the wheel drive shaft vertically in the vise.

Note: Insert a small flat-bladed screwdriver between the retaining ring and the outer race

8. Using a flat bladed screwdriver, remove the retaining ring from the outer race.
9. Relocate the retaining ring away from the CV joint.




Note:  Use the boot to catch any of the bearings that may fall out of the cage and inner race when the outer race is removed.

10. Remove the outer race from the wheel drive shaft axle.



11. Remove any remaining bearings balls from the cage and inner race.
12. Remove any of the bearing that fell into the boot.



13. Using the J 35910 pliers , remove the retaining ring from the wheel drive shaft.



14. Align the cage lands with the inner race ball tracks.
15. Reposition the cage along the axle shaft away from the inner race.
16. Remove the lubricant from the inner race.
17. Using the appropriate tool, remove the inner race from the axle shaft.



18. Remove the cage from the wheel drive shaft.



19. Remove the boot from the wheel drive shaft.
20. Remove the wheel drive shaft from the bench vise.

Note: If any of the following components are found to have excessive wear or are damaged, replace the wheel drive shaft as an assembly.

21. Thoroughly clean the following components with the proper cleaning solvent:

•	The inner race

•	The outer race

•

The cage

•

The balls

•	The axle shaft exposed end

22. Thoroughly air dry all the parts.

Caution: Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.

1. Wrap a shop towel around the wheel drive shaft
2. Install the wheel drive shaft horizontally in a bench vise.
3. Install the NEW boot and clamp on the wheel drive shaft.




Note: Install the cage so that the smaller diameter of the cage is facing the vise.

4. Install the cage on the wheel drive shaft.




Note: The inner race spline relief must face away from the end of the axle shaft

5. Install the inner race on the wheel drive shaft.

Note: Ensure that the inner race spline relief side is installed on the wheel drive shaft first.

6. Position the inner race splines on the wheel drive shaft.

Note: Ensure that the inner race is fully seated on the heel drive shaft and the retaining ring can be seen.

7. Using a block of wood and a hammer, install the inner race on the wheel drive shaft



8. Using the appropriate tool, install the retaining ring on the wheel drive shaft.
9. Position the cage so the cage lands align with the inner race ball tracks.
10. Install the cage onto the inner race.
11. Position the cage windows to align with the inner race ball tracks.



12. Insert approximately 60 % of the lubricant into the outer race.



13. Position the wheel drive shaft vertically in the bench vise so the inner joint end is up.
14. Apply a small amount of the lubricant to the cage windows and inner race ball tracks.
15. Insert the remaining lubricant into the boot.




Note: Position the retaining ring below the cage toward the vise.

16. Install the outer race retaining ring on the wheel drive shaft.

Note: Use the seal to keep the balls in position if necessary.

17. Install the bearings through the cage windows to the inner race ball tracks.
18. Install the outer race onto the axle shaft.




Note: Be careful not to allow the grease in the outer race to leak out.

19. Align the outer race ball tracks to the balls.
20. Slide the outer race down over the balls.
21. Position the wheel drive shaft horizontally in the bench vise.
22. Slide the outer race toward the vise.
23. Engage the outer race retaining ring.
24. Insert the outer race retaining ring into the groove along the outer edge of the outer race.
25. Position the outer race retaining ring so the opening in the ring aligns with an outer race land (not a ball track).
26. Position the large diameter end of the seal onto the outer race.



27. Position the small boot clamp (3) on the neck of the boot (4).
28. Position the seal and small clamp to the wheel drive shaft (2).
29. Measure the distance (1) between the edge of the seal and the edge of the last axle shaft groove closing edge should be 2.5 mm (0.10 in) adjust fit accordingly.




Note: Ensure that the clamp is securely closed and seated on the boot.

30. Using the CH 48894 pliers  (1), close the boot clamp (3).



31. Adjust the plunging motion of the joint accordingly until the measure the distance (1) between the end of the seal and the end of the joint outer race is 224-228 mm (8.82-8.98 in).



32. Position the large clamp (2) on the boot (3).
33. Position the boot and large clamp to the joint outer race (4) as shown.
34. Adjust the boot until the measure the distance (1) between the edge of the seal and the edge of the joint outer race last groove closing edge is 0.8 mm (0.03 in).

Note: The boot must not be distorted in any way. If the seal is NOT shaped correctly, equalize the pressure in the seal and shape the seal properly by hand.

35. Inspect the seal for proper shape.

Note: If the boot has been cut or punctured during assembly, replace the boot.

36. Inspect the boot for damage.
37. Ensure that the boot is properly seated on the CV joint housing.




Note: Ensure that the clamp is fully engaged in the boot clamp band.

38. Using the J 42572 tool , lock the boot clamp.
39. Remove the wheel drive shaft from the bench vise.
40. Move the CV joint in a circular motion 4 or 5 times to distribute the lubricant with the CV joint.
41. Inspect the inner CV joint and wheel drive shaft for smooth operation.
42. Install the wheel drive shaft into the vehicle. Refer to Wheel Drive Shaft Replacement.

Wheel Drive Shaft Inner Joint and Boot Replacement W Z06, Z51

Special Tools

Note: If the outer joint is found to have excessive wear or damaged inner components, replace the wheel drive shaft as an assembly. The outer joint and it's inner components are not serviced.

1. Remove the wheel drive shaft from the vehicle. Refer to Wheel Drive Shaft Replacement.



2. Install wheel drive shaft bar in a soft jawed vise and clamp securely.
3. Using side cutters, remove and discard the inner boot clamp.



4. Using a flat-bladed tool, remove and discard the outer boot clamp.



5. Remove the boot from the tripot housing and reposition the boot on the wheel drive shaft.
6. Remove the tripot housing from the wheel drive shaft.



7. Using the J 8059 pliers , remove the retaining ring (1) and the tripot spider (2) from the wheel drive shaft (3).

Note: The rollers may fall off the spider assembly when the tripod joint is removed from the housing

8. Remove the spider assembly and the tripot housing from the wheel drive shaft.



9. Remove the boot (1) from the wheel drive shaft (2).
10. Remove the excess lubricant from the face of the tripot spider and the inside of the tripot housing.

Note: If the inner tripot assembly is found to have worn or damaged internal parts, replace the wheel drive shaft as an assembly. The tripot assembly and it's inner components are not serviced separately.

11. Inspect the inner tripot assembly for wear or damage. Refer to Wheel Drive Shaft Inner Joint Inspection

1. Install the boot and the clamp (1) on the wheel drive shaft (2).



2. Ensure that the boot  (1) is properly seated in the groove (2) in the wheel drive shaft (3).




Note: Ensure that the boot clamp is properly positioned around the entire circumference of the boot.

3. Using the J35910 pliers  (1), close the boot clamp (2)  until the measured gap (3) is between  1 and 4 mm (0.038 and 0.157 in).




Note: Ensure that the tripot spider is seated against shoulder on the wheel drive shaft.

4. Install the tripot spider (2) on the wheel drive shaft (3).
5. Using the J 8059 pliers , install the retaining ring  (1) on the wheel drive shaft.



6. Place approximately half of the container of lubricant (2) in the boot (2) and half in the tripot housing (3).



7. Install the tripot assembly and the boot clamp on the spider assembly.




Note: Ensure that the seal is properly seated in the groove of the tripod housing.

8. Using the J35910 pliers  (3), breaker bar (5), torque and or ratchet wrench (4), close the clamp until the measured gap (6) is between 1 and 4 mm (0.038 and 0.157 in).
9. Move the tripot housing in a circular motion 4 or 5 times to distribute the lubricant in the tripot assembly.
10. Remove the excess lubricant from the wheel drive shaft.
11. Install the wheel drive shaft in the vehicle. Refer to Wheel Drive Shaft Replacement.