Front Wheel Drive Shaft Inner Joint and Boot Replacement Delphi

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. Disconnect the swage ring from the halfshaft bar using a hand grinder to cut through the ring, taking care not to damage the halfshaft bar.
2. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp.
3. Separate the inboard seal from the trilobal tripot bushing (3) at the large diameter.
4. Slide the seal away from the joint along the halfshaft bar.



5. Remove the housing (1) from the tripot joint spider and the halfshaft bar (2).



6. Remove the spacer ring (1), spider assembly (2), spacer ring (3) using J 8059 , and tripot boot (4). Discard the boot and rings.
7. Clean the halfshaft bar (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves).
8. 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 kit.

1. Place the new small swage ring (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the small swage ring (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.



3. Mount J 41048 in a vise and proceed as follows:

3.1.	Position the inboard end (1) of the halfshaft assembly in tool J 41048 .

3.2.	Align the top of seal neck on the bottom die using the indicator.

3.3.	Place the top half of the J 41048 on the lower half .

3.4.	Before proceeding, ensure there are no pinch points on the halfshaft inboard seal. This could cause damage to the halfshaft inboard seal.

3.5.	Insert the bolts (2).

3.6.	Tighten the bolts by hand until snug.

Notice: Refer to Fastener Notice in the Preface section.




4. Align the following items:

•	The halfshaft inboard seal (1)

•	The halfshaft bar

•	The swage ring (2)

Tighten
Tighten each bolt of J 41048 , 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.




5. Install the spacer ring (2) into the groove of the halfshaft bar using J 8059 .



6. Slide the tripot joint spider assembly (4) toward the spacer ring (1) as far as it will go on the halfshaft bar.
7. Install the spacer ring (2) into the groove of the halfshaft bar J 8059 .



8. 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.

Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).

9. Install the new trilobal tripot bushing (3) to housing (1).
10. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal.
11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.



12. 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 and locate the lip of the seal in the groove.

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

13. Position the joint assembly at the proper vehicle dimension.

•	For 4.0L and 3.8L supercharged engine vehicles, dimension a = 111 m (4.37 in).

•	For 3.8L engine vehicles, dimension a = 95 mm (3.75 in).




14. Align the following items while latching:

•	The halfshaft inboard seal

•	The tripot housing (2)

•	The large seal retaining clamp (3)

Tighten
Crimp the seal retaining clamp with J 35910 to 176 N·m (130 lb ft). Add the breaker bar (5) and the torque wrench (4) to J 35910 if necessary.

15. Inspect the gap dimension (a) on the clamp ear. If gap dimension is larger than shown, continue tightening until gap dimension of 2.60 mm (0.102 in) is reached.
16. Fully stroke the joint several times to disperse the grease.