Special Tools

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

Important: Before placing the driveshaft in a vise, place protective covers over the vise jaws.

2. Place the driveshaft in a vise.




Important: Do not damage the D/O joint housing while using the hand grinder.

3. Use a hand grinder to cut through the large retaining clamp (2) located at the D/O joint (1).

Discard the large retaining clamp.

4. Use a hand grinder to cut through the small retaining clamp (4) on the small end of the seal (3).

Discard the small retaining clamp.




5. Slide the seal (2) down the driveshaft bar and away from the D/O joint (1).



6. Remove the D/O joint housing in the following manner:
7. Collapse and remove the D/O ball retaining ring using a common hand tool (screwdriver).
8. Pull the D/O joint housing from the driveshaft bar.



9. Using pliers J 8059 , spread the small retaining ring (1) located in the cage and inner race assembly (3).



10. Remove the cage and the inner race assembly (1) from the driveshaft bar (2).
11. Remove the balls.
12. Remove the inner race from the cage.
13. Thoroughly degrease all parts.
14. Remove the seal and discard.
15. Clean the driveshaft bar, Use a wire brush to remove any remove any rust in the seal mounting areas (grooves).

Check the D/O joint housing for unusual wear, cracks, or other damage. Replace the assembly if any damaged parts are evident.

1. Install the new small retaining clamp (2) onto the neck of the seal (1).
2. Slide the small retaining clamp and seal to their proper position on the driveshaft bar (3).

Notice: Refer to Fastener Notice in the Preface section.

3. Secure the small retaining clamp using the pliers J 35910 or equivalent, a breaker bar, and a torque wrench.

Tighten
Tighten the small retaining clamp (2) to 136 N·m (100 lb ft).





Important: The cage (3) is NOT symmetrical; the larger outside diameter is the bottom of the cage.

4. Place the cage on the table large diameter side up.
5. Place the inner race (2) with retaining ring side up into the cage.
6. Place the six balls (1) in the cage windows.
7. Slide the cage/inner race assembly, small diameter first, onto the driveshaft bar.



8. Install the small retaining ring (1) using pliers J 8059 into the groove of the driveshaft bar.



9. Pack the seal and D/O joint housing with the grease suppled in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
10. Place the new large retaining clamp on the seal.
11. Slide the D/O joint housing over the cage and inner race assembly.



12. Insert the D/O ball retaining ring into the groove at the top of the D/O joint housing.



13. Install the seal onto the D/O joint housing.



14. Check the inboard stroke position.



15. Install a new large retaining clamp. Crimp the large retaining clamp using the pliers CH-48894 (1).

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

16. Fully stroke the D/O joint several times to disperse the grease.
17. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement.