Special Tools

Caution: 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. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. Discard the retaining clamp.
2. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp.
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 the spacer ring (1) using J 8059 (or equivalent).



7. Remove the spacer ring (1), spider assembly (2), spacer ring (3) (if equipped) using J 8059 , and tripot boot (4). Discard the boot and rings.
8. Clean the halfshaft bar (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves).
9. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit.

Note: Place a towel in the vise before inserting the halfshaft.

1. Mount the halfshaft into a vise.
2. Place the new small eared clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the eared clamp (2) onto the halfshaft bar.
3. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.



4. Crimp the eared clamp (6) using J 35910 , a torque wrench (8), and a breaker bar (9).



5. If equipped, install the spacer ring (2) into the groove of the halfshaft bar using J 8059 .



6. Slide the tripot joint spider assembly (4) as far as it will go on the halfshaft bar.
7. Install the spacer ring (2) into the groove of the halfshaft bar J 8059 .



8. Place approximately half of the grease from the service kit in the halfshaft inboard seal. Use the remainder of the grease to repack the housing.

Note: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).

9. Install the trilobal tripot bushing (3) to housing (1).
10. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal.
11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.



12. Slide the large diameter of the halfshaft inboard seal (2), with larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.
13. Position the joint assembly at the proper vehicle dimension, a = 106 mm (4.00 in).
14. Carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the trilobal tripot bushing in order to equalize the pressure. Remove the tool.



15. Align the following items while latching:

•	The halfshaft inboard seal

•	The tripot housing (2)

•	The large seal retaining clamp (3)--Crimp the seal retaining clamp with J 35910 to 176 N·m (130 lb ft). Add the breaker bar (5) and the torque wrench (4) to J 35910 if necessary.

16. Check the gap dimension (a) on the clamp ear. If the gap dimension is larger than shown, continue tightening until the gap dimension of 2.6 mm (0.102 in) is reached.
17. Fully stroke the joint several times to disperse the grease.