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 (2).
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. Spread spacer ring (2) using J 8059 .



7. Slide the spacer ring (3) and the tripot joint spider (2) back on the halfshaft bar (4).
8. Remove the halfshaft bar retaining ring (1) from the groove on the halfshaft bar.
9. Slide tripot joint spider assembly (2) off of the halfshaft bar (4).
10. Clean the tripot joint spider assembly (2) and the housing thoroughly with cleaning solvent.
11. Remove all traces of old grease and any contaminates. Dry all the parts.
12. Remove the trilobal tripot bushing from the housing and discard the old bushing.
13. Remove the spacer ring (3) and the seal from the halfshaft bar (4). Discard the old seal and ring.
14. Inspect the following parts for damage or wear:

•	The tripot joint spider assembly (2)

•	The housing

•	The halfshaft bar (4)

1. Install the new swage ring (2) on the neck of the new inboard seal (1). Do not swage.
2. Slide the halfshaft inboard seal (1) onto the halfshaft bar.
3. Position the neck of the halfshaft inboard seal (1) in the seal groove (3) on the halfshaft bar.



4. Position the inboard end of the halfshaft assembly (1) using J 41048 .




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.

5. Align the swage ring (2) by performing the following steps:

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

Important: Align the following items:    •  The inboard seal (1)    •  The halfshaft bar    •  The swage ring (2)

5.2.	Insert the bolts.

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.

5.3.	Tighten the bolts by hand until snug.

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

5.4.	Loosen the bolts.

5.5.	Separate the dies.

5.6.	Check the swage ring (2) for any "lip" deformities. If present, place the ring (2) back into the J 41048 ensuring the swage ring (2) covers the whole swaging area.

5.7.	Re-swage the swage ring (2).




6. Install the spacer ring (3) on the halfshaft bar (4) and beyond the second groove.
7. Slide the tripot joint spider assembly (2) toward the spacer ring (3) as far as it will go on the halfshaft bar (4).
8. Install the halfshaft bar retaining ring (1) in the groove of the halfshaft bar (4) using J 8059 .
9. Slide the tripot joint spider assembly (2) towards the end of the halfshaft bar (4).
10. Reseat the spacer ring (1) in the groove on the halfshaft bar (4).
11. Place approximately half of the grease from the service kit in the inboard seal. Use the remainder of the grease to repack the housing.
12. Install the trilobal tripot bushing to housing. Ensure the trilobal tripot bushing is flush with the face of the housing.
13. Position the larger new clamp on the inboard seal.
14. Slide the housing over the tripot joint spider assembly on the halfshaft bar.
15. Slide the large diameter of the inboard seal, with the larger clamp in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.




Important: The inboard seal (2) must not be dimpled, stretched out or out of shape in any way. If the 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 inboard seal properly by hand. Remove the tool.

16. Position the joint assembly at the proper vehicle dimension (dimension a= 105 mm (4 in)).




Important: Align the following items while latching:

•	The inboard seal

•	The housing (2)

•	The large seal retaining clamp (3)

17. Crimp the seal retaining clamp (3) with J 35910 .

Tighten
Crimp the clamp (3) to 174 N·m (130 lb ft).

18. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached (dimension a= 2.3 mm (3/32 in) maximum).