Tools Required

J 8059 Snap Ring Pliers

Notice: With the removal of the wheel drive shaft for any reason, the transmission sealing surface (the tripot male/female shank of the joint) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent in a rotational motion only. Do not clean with an oscillating motion. Transmission fluid may be used to clean off any remaining debris and the joint wiped dry before installation. Corrosion on the joint sealing surface may damage the transmission seals and cause a fluid leak.




1. Use a hand grinder in order to cut through the swage ring (2). Do not damage the tripot housing (1).
2. Remove the tripot housing (1) from the halfshaft.
3. Wipe the grease off of the tripot assembly roller bearings and the tripot housing (1).
4. Thoroughly degrease the tripot housing (1).
5. Allow the tripot housing (1) to dry prior to assembly.




Important: Handle the tripot spider assembly with care. Tripot balls and needle rollers may separate from the spider trunnion if the tripot balls and needle rollers are not handled carefully.

6. Use side cutters to cut away the small boot clamp.
7. Spread the spider spacer ring (2) with J 8059 (or equivalent).



8. Remove the following items from the halfshaft bar:

8.1.	The spacer ring (1)

8.2.	The spider assembly (2)

8.3.	The tripot boot (3)

9. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the boot mounting area (grooves).
10. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts.

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



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

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

4. Check the gap dimension on the clamp ear.




Important: You must assemble the inboard joint with the convolute retainer in the correct position, as illustrated. The inboard joint boot will be damaged if the inboard joint assembly does not meet the specified dimension.

5. Install the convolute retainer over the inboard joint boot, being sure to capture three convolutions.



6. Install tripot spider assembly (3) onto the halfshaft bar (2) with the counterbore towards the end of the halfshaft bar (2).
7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2).
8. Push the spider assembly (3) back toward the end of the halfshaft bar (2) until the spacer ring is covered by the spider assembly (3) counterbore.
9. Pack the tripot boot and the tripot housing with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.



10. Reassemble the tripot housing (1) and the tripot boot using the following procedure:

10.1.

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

10.2.

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

10.3.

Place the tripot housing (1) over the spider assembly (3).

10.4.

Install the boot onto the tripot housing (1).

10.5.

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




11. Mount J 36652 in a vise.
12. Install the bottom half of the split-plate swage clamp. For K10 models, use J 36652 -98.
13. For K20/K30 models, use J 36652 -1.



14. Check the inboard stroke position.

•	Use measurement A for the K10 models.

•	Use measurement B for the K20 and K30 models.




15. Position the inboard end (tripot end) of the halfshaft assembly in J 36652 .
16. Install the top half of the proper size tool on the lower half of the tool. For K10 models, use J 36652 -98.
17. For K20/K30 models, use J 36652 -1
18. Align the swage ring (2) and the swage ring clamp.
19. Insert the bolts.

Tighten
Hand tighten the bolts in J 36652 until the bolts are snug.

20. Align the following during this procedure:

•	The tripot boot (3)

•	The 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 J 36652 touch the bottom half of the J 36652 .




21. Loosen the bolts and remove the halfshaft assembly from J 36652 .
22. Remove the convolute retainer from the boot.