Special Tools

1. Place the halfshaft in a vise.
2. Place protective covers over the vise jaws.



3. Use a hand grinder to cut through the swage rings (2). Do not damage the outer race.
4. Compress the seal on the halfshaft and away from the constant velocity (CV) joint outer race (1).
5. Wipe all grease away from the face of the CV joint.



6. Find the halfshaft retaining snap ring (3), which is located in the inner race (2).
7. Spread the snap ring ears apart using J 8059 (or equivalent).
8. Pull the CV joint from the halfshaft (4).
9. Discard the old seal.



10. Place a brass drift against the cage (1).
11. Tap gently on the brass drift in order to tilt the cage.
12. Remove the first ball (2) when the cage tilts.
13. Repeat the previous step to remove all of the balls.



14. Pivot the cage (4) and the inner race 90 degrees to the centerline of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2).
15. Lift out the cage (4) and the inner race.



16. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward.
17. Thoroughly degrease all of the CV joint parts.
18. Check the outer CV joint assembly for unusual wear, cracks, or other damage. Replace any damaged parts.
19. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).

Note: Replace the joint assembly if necessary.

1. Inspect all of the parts for unusual wear, cracks, or other damage.
2. Put a light coat of the recommended grease on the inner and the outer race grooves.
3. Insert the inner race (1) into the cage (2) by rotating the inner race downward.
4. Hold the inner race (1) at 90 degrees to the centerline of the cage.



5. Align the lands of the inner race (2) with the windows of the cage (3).
6. Rotate the inner race downward to insert the inner race into the cage.
7. Insert the cage (4) and inner race into the outer race (1).



8. Place a brass drift against the cage (1).
9. Tap gently on the brass drift in order to tilt the cage (1).
10. Install the first ball (2) when the cage tilts.
11. Repeat previous step to reinstall all of the balls.



12. Pack the CV joint seal and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
13. Place the new small swage clamp (2) onto the CV joint seal (1).
14. Place the large retaining clamp on the seal (1).
15. Position the small end of the CV joint seal (1) into the joint seal groove (3) on the halfshaft bar.



16. Position the outboard end of the halfshaft assembly (1) in J 41048 .



17. Align the swage clamp (2) within J 41048 .



18. Place the top half of the J 41048 on the bottom half.
19. Check to make sure there are no pinch points on the seal before proceeding with procedures.
20. Insert the bolts (2). Tighten the bolts (2) by hand until snug.

Caution: Refer to Fastener Caution in the Preface section.

21. Align the following items:

•

The seal

•	The halfshaft bar

•	The swage clamp

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

22. Loosen the bolts.
23. Separate the dies.
24. Check the swage clamp for any "lip" deformities. If the deformities exist, place the swage clamp back into the J 41048 .




Note: Ensure that the retaining ring side of the CV joint inner race faces the halfshaft bar (1) before installation.

25. Place the retaining snap ring into the CV joint inner race.

Note: The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint is in the proper position.

26. Slide the CV joint (2) onto the halfshaft bar (1).
27. Pull on the CV joint (2) to verify engagement.



28. Slide the large diameter of the CV joint seal (1), with the large retaining ring (2) in place, over the outside edge of the CV joint outer race (3).
29. Position the lip of the CV joint seal (1) into the groove on the CV joint outer race (3).
30. Manipulate the CV joint seal (1) to remove any excess air.



31. Secure the large retaining clamp (1) to the housing with J 35910 (or equivalent), a breaker bar (3), and a torque wrench (2).

Torque the large retaining clamp (1) to 176 N·m (130 lb ft).

32. Check the gap dimension on the clamp ear.