Tools Required

J 8059 Snap Ring Pliers

1. Remove the large boot clamp (3) from the tripot boot (4) with side cutters.
2. Remove the tripot housing (1) and bushing (2) from the halfshaft bar (5). Wipe the grease off of the tripot assembly roller bearings and housing.
3. Degrease the housing (1) and the bushing (2) thoroughly. Use 320 grit 3M cloth (or equivalent) to remove any evident corrosion in the transmission booting surface.
4. Allow the housing (1) and the bushing (2) to dry prior to assembly.



5. Cut the small boot clamp from the halfshaft bar end of the tripot boot, using side cutters.

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. Slide the tripot boot up the halfshaft bar (1), away from the tripot spider assembly toward the outboard (CV joint assembly) end of the halfshaft bar.
7. Spread the spider spacer ring (2) using J 8059 (or equivalent).



8. Slide the spider spacer ring (3) and the tripot spider assembly (2) up on the halfshaft bar (4). This will provide access to the halfshaft bar retaining ring (1) which is in the groove at the end of the halfshaft bar (4).



9. Remove the retaining ring (1), spider assembly (2), spacer ring (3), and tripot boot (4).
10. Clean the halfshaft bar (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves).
11. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts.

Tools Required

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



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

Tighten
Torque the small boot clamp (1) to 136 N·m (100 lb ft). Check the gap dimension on the clamp ear.





Important: Assemble the joint with the convolute retainer in the correct position. The boot will be damaged if the joint assembly does not meet the specified dimension.

5. Install the convolute retainer over the inboard boot, capturing three convolutions.



6. Install the first spacer ring and tripot spider assembly onto the halfshaft bar, with the counterbore towards the end of the halfshaft bar.
7. Push the first spacer ring and the tripot spider assembly onto the halfshaft bar far enough to allow for installation of the second spacer ring in the groove at the end of the halfshaft bar.
8. Install the second spacer ring in the groove at the end of the halfshaft bar.



9. Push the spider assembly (1) back toward the end of the halfshaft bar (3) until the retaining ring is covered by the spider assembly counterbore.
10. Move the spider spacer ring (2) back toward the end of the halfshaft bar. Seat the spider spacer ring (2) in the spacer ring groove. Make sure the spider spacer ring is fully seated.
11. 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.



12. Place the large retaining clamp (2) on the boot.
13. Place the housing (1) over the spider assembly (3).
14. Install the boot onto the housing (1).



15. Check the inboard stroke position.



16. Secure the large retaining clamp (2) and the boot (3) to the housing (1) using J 35566 .

Tighten
Torque the large retaining clamp (2) to 176 N·m (130 lb ft).

17. Check the gap dimension on the clamp ear.



18. Remove the convolute retainer from the boot (1).